Operating Instructions Diesel engine - MTU · PDF fileOperating Instructions Diesel engine 8 V 2000 M40A, 8 V 2000 M40B 12 V 2000 M40A, 12 V 2000 M40B 12 V 2000 M41A, 12 V 2000 M41B

Operating InstructionsDiesel engine8 V 2000 M40A, 8 V 2000 M40B12 V 2000 M40A, 12 V 2000 M40B12 V 2000 M41A, 12 V 2000 M41B16 V 2000 M40A, 16 V 2000 M40B16 V 2000 M41A, 16 V 2000 M41B

MS150031/03E

Printed in Germany© 2011 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without the priorwritten permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐filming and storage or processing on electronic systems including data bases and online services.This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damageduring operation.Subject to alterations and amendments.

Commissioning NoteImportantPlease complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ranty, spare parts, etc.).

Table of Contents1 Safety

1.1 General conditions 81.2 Personnel and organizational requirements 91.3 Transportation 101.4 Safety precautions when working on the

engine 131.5 Fluids and lubricants, fire prevention and

environmental protection 151.6 Conventions for safety instructions in the

text 17

2 Product Summary

2.1 Product description 182.2 Series 2000 M40A/B - M41A/B 272.3 Engine side and cylinder designations 282.4 Engine – Main dimensions 292.5 Firing order 302.6 Technical Data 31

2.6.1 8V 2000 M40A engine data: engine-mountedheat exchanger, reference conditions: 25 °Cintake air temperature 31

2.6.2 8V 2000 M40A engine data: separate heatexchanger, reference conditions: 25 °C intakeair temperature 34

2.6.3 8V 2000 M40B engine data, engine-mountedheat exchanger, reference condition: 25 °Cintake air temperature 37

2.6.4 8V 2000 M40B engine data, separate heatexchanger, reference condition: 25 °C intakeair temperature 40

2.6.5 12V 2000 M40A engine data: Engine-mounted heat exchanger, referenceconditions: 45 °C intake air temperature 43

2.6.6 12V 2000 M40A engine data: Engine-mounted heat exchanger, referenceconditions: 25 °C intake air temperature 46

2.6.7 12V 2000 M40A engine data: Separate heatexchanger, reference conditions: 25 °C intakeair temperature 49

2.6.8 12V 2000 M40A engine data: Separate heatexchanger, reference conditions: 45 °C intakeair temperature 52









2.6.17 ENGINE DATA 12V 2000M41A/B 792.6.18 ENGINE DATA 16V 2000M41A/B 82

3 Operation

3.1 LOP – Controls 853.2 Putting the engine into operation (out-of-

service period > 3 months) 873.3 Putting the engine into operation after

scheduled out-of-service period 883.4 Starting the engine from LOP 893.5 Operational checks 903.6 Stopping the engine at the LOP 913.7 Emergency stop from LOP 923.8 After stopping the engine 933.9 Plant – Cleaning 94

4 Maintenance

4.1 Maintenance task reference table [QL1] 95

5 Troubleshooting

5.1 Troubleshooting 965.2 LOP alarms 99

6 Task Description

6.1 Engine 1046.1.1 Engine – Barring manually 1046.1.2 Engine – Barring with starting system 105

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6.2 Cylinder Liner 1066.2.1 Cylinder liner – Endoscopic examination 1066.2.2 Instructions and comments on endoscopic

and visual examination of cylinder liners 108

6.3 Crankcase Breather 1106.3.1 Crankcase breather – Oil separator element

replacement, diaphragm check andreplacement 110

6.3.2 Crankcase breather – Cleaning oil separatorelement 112

6.3.3 Crankcase breather – Oil separatorreplacement, diaphragm check andreplacement 113

6.4 Valve Drive 1156.4.1 Valve clearance – Checking and adjusting 1156.4.2 Cylinder head cover – Removal and

installation 118

6.5 Injection Pump / HP Pump 1196.5.1 Injection pump – Replacement 1196.5.2 Injection pump – Removal and installation 120

6.6 Injection Valve / Injector 1236.6.1 Injector – Replacement 1236.6.2 Injector – Removal and installation 124

6.7 Fuel System 1286.7.1 HP fuel line – Pressure pipe union

replacement 1286.7.2 Fuel – Draining 1306.7.3 Fuel system venting 131

6.8 Fuel Filter 1336.8.1 Fuel filter – Replacement 1336.8.2 Fuel prefilter – Differential pressure check and

adjustment of gauge 1356.8.3 Fuel prefilter – Draining 1366.8.4 Fuel prefilter – Flushing 1376.8.5 Fuel prefilter – Filter element replacement 139

6.9 Charge-Air Cooling 1416.9.1 Intercooler – Checking condensate drain line

for coolant discharge and obstruction 141

6.10 Air Filter 1426.10.1 Air filter – Replacement 1426.10.2 Air filter – Removal and installation 143

6.11 Air Intake 1446.11.1 Service indicator - Signal ring position check 144

6.12 Starting Equipment 1456.12.1 Starter – Condition check 145

6.13 Lube Oil System, Lube Oil Circuit 1466.13.1 Engine oil level – Check 1466.13.2 Engine oil – Change 147

6.14 Oil Filtration / Cooling 148

6.14.1 Oil dipstick – Marking 1486.14.2 Engine oil filter – Replacement 1496.14.3 Centrifugal oil filter – Cleaning and filter-

sleeve replacement 151

6.15 Coolant Circuit, General, High-Temperature Circuit 154

6.15.1 Drain and venting points 1546.15.2 Engine coolant – Level check 1596.15.3 Engine coolant – Change 1606.15.4 Engine coolant – Draining 1616.15.5 Engine coolant filling 1626.15.6 HT coolant pump – Relief bore check 1636.15.7 Engine coolant – Sample extraction and

analysis 164

6.16 Raw Water Pump with Connections 1656.16.1 Raw water pump – Relief bore check 165

6.17 Belt Drive 1666.17.1 Drive belt – Condition check 166

6.18 Battery-Charging Generator 1676.18.1 Battery-charging generator drive – Drive belt

check and adjustment 1676.18.2 Battery-charging generator drive – Drive belt

replacement 169

6.19 Engine Mounting / Support 1716.19.1 Engine mounting – Checking condition of

resilient mounts 171

6.20 Wiring (General) for Engine/Gearbox/Unit 1726.20.1 Engine wiring – Check 172

6.21 Accessories for (Electronic) EngineGovernor / Control System 173

6.21.1 Engine control unit and connectors – Cleaning 1736.21.2 Engine monitoring unit and connectors –

Cleaning 1746.21.3 Start interlock limit switch – Check 1756.21.4 ECU – Checking plug connections 1766.21.5 Engine monitoring unit, plug connections –

Check 1776.21.6 Engine control unit – Removal and installation 178

6.22 Emergency Instrumentation (LocalOperating Panel) 180

6.22.1 LOP and connectors – Cleaning 1806.22.2 LOP – Visual inspection 1816.22.3 LOP – Test procedures 183

7 Appendix A

7.1 Abbreviations 1857.2 MTU contacts/service partners 187

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8 Appendix B

8.1 Special Tools 188

8.2 Consumables 1928.3 Index 194

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1 Safety1.1 General conditions

GeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pulsory regulations regarding accident prevention and environmental protection must be observed. Thisstate-of-the-art engine has been designed to meet all applicable laws and regulations. The engine maynevertheless present a risk of injury or damage in the following cases:• Incorrect use• Operation, maintenance and repair by unqualified personnel• Modifications or conversions• Noncompliance with the Safety Instructions

Correct useThe engine is intended solely for use in accordance with contractual agreements and the purpose envis‐aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts noliability whatsoever for resultant damage or injury in such case. The responsibility is borne by the useralone.Correct use also includes observation of and compliance with the operating instructions and mainte‐nance and repair specifications.

Modifications or conversionsUnauthorized modifications to the engine represent a safety risk.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications orconversions.

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. MTU accepts noliability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shallbe voided in such case.

Reworking componentsRepair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirements

Personnel requirementsWork on the engine must only be carried out by appropriately qualified and instructed personnel.Observe the minimum legal age.Responsibilities of the operating, maintenance and repair personnel must be specified by the operatingcompany.

Organizational measuresThis publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐tion.Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair andtransport personnel at all times.Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐nel must have read and understood the safety-relevant instructions.This is especially important for personnel who work on the engine only on an occasional basis. Thesepersons shall receive repeated instruction.Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipmentWear proper protective clothing for all work.Depending on the kind of work, use the necessary personal protective equipment.

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1.3 Transportation

Transport without flange-mounted gearboxIllustration is essentially valid for 8V 2000 M engines

Illustration is essentially valid for 12/16V 2000 M engines

Transport with flange-mounted gearboxIllustration is essentially valid for 8V 2000 M engines

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Illustration is essentially valid for 12/16V 2000 M engines

Only use the lifting eyes provided to lift the engine.The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plantswith flange-mounted gearboxes.Only use transport and lifting devices approved by MTU.Take the engine's center of gravity into account.

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The engine must only be transported in installation position, max. permissible diagonal pull 10°.If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐portation.Secure the engine against tilting during transport. In particular when going down inclines or ramps, theengine must be secured against moving and tilting.

Setting the engine down after transportOnly set down engine on a firm, level surface.Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

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1.4 Safety precautions when working on the engine

Safety requirements for maintenance and repair work• Maintenance and repair work may only be carried out by authorized, qualified personnel.• Allow the engine to cool down before commencing maintenance work (oil vapors present a risk of ex‐

plosion).• Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.• Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with

a rag to prevent fluids escaping under pressure.• Take special care when draining hot fluids ⇒ risk of burning.• When changing the engine oil or working on the fuel system, ensure that the engine room is ade‐

quately ventilated.• Prior to all work, allow the engine / genset to cool down.• Observe maintenance and repair instructions.• Never perform care or maintenance work with the engine running unless expressly instructed to do so.• Lock-out/tag-out the engine to preclude undesired starting.• With electric starter, disconnect the battery.• Close the main valve on the compressed-air system and vent the compressed-air line when air start‐

ers are fitted.• Disconnect the control device from the assembly or plant.• Only use adequate, calibrated tools.During assembly and disassembly, observe the specified tighten‐

ing torques.• Carry out work only on assemblies or plants that are secured as specified.• Do not use lines as climbing aids.• Keep fuel injection lines and connections clean.• Always fit caps/covers to close off any openings exposed by removing or opening lines.• Take care to avoid damaging fuel lines in the course of care and maintenance work.• Ensure that all mounts and dampers are correctly installed.• Ensure that all fuel injection and pressurized oil lines are installed with enough space to prevent con‐

tact with other components. Do not place fuel or oil lines near hot components.• Do not touch elastomeric seals (e.g. Viton sealing rings) if they have carbonized or resinous appear‐

ance.• Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!• When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐

nents are placed on stable surfaces.• Observe special cleanness during maintenance and repair work on the assembly or plant. After com‐

pletion of maintenance and repair work, make sure that no loose objects are in/on the assembly orplant.

• Ensure that all personnel is clear of danger zones before turning the engine. Check that all guardshave been reinstalled and that all tools and loose parts have been removed after working on the en‐gine.

• If starters with beryllium copper pinions are installed, the following also applies:To avoid health risks with the pinion containing beryllium, breathing protection of filter class P2 mustbe worn during maintenance work. Do not blow out the interior of the flywheel housing and the starterwith compressed air. The interior of the flywheel housing must be additionally cleaned with a dust-removal machine of class H.

Welding workNever carry out welding work on the assembly or engine plant or mounted units. Cover the engine whenwelding in its vicinity.Do not use the assembly or plant as a ground terminal.Never place the welding cable across or near wiring harnesses of MTU plants. The welding current mayotherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐tem.

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If welding has to be carried out on components (e.g. exhaust manifold), these components must first beremoved from the engine.

Hydraulic installation and removalCheck the tools and devices to be used for perfect operation and safe condition. Only use the specifieddevices for force-fitting/removing parts.Observe the maximum press-on pressure for the device for force-fitting/removing parts.Do not attempt to bend or exert force on H.P. lines.Observe the following before starting the pressing procedure:• Bleed air from jigs and fixtures for force-fitting/removing parts, pumps and piping at the points provid‐

ed for the system concerned (e.g. open threaded vent plugs, pump until no bubbles can be discernedin the oil, close threaded vent plugs).

• During the installation procedure, screw on device with pushed-in plunger.• During the removal procedure, screw on device with retracted plunger.For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaftend until correct sealing is established.During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity ofthe component being pressed.

Working on electrical/electronic assembliesBefore starting any maintenance or repair work, or before switching off any electronic components nec‐essary to carry out the work, permission must first be obtained from the relevant manager or supervisor.Before work is carried out on the assemblies, the power supply to the relevant areas must be switchedoff.Do not damage wiring during the removal work. When reinstalling, ensure that the wiring cannot be dam‐aged during engine operation through contact with sharp edges, rubbing against a component or throughcontact with a hot surface.Do not secure cables on lines carrying fluids.Do not use cable clamps to secure the lines.Only tighten union nuts of connectors with connector pliers.On completion of all repair work, the device or system must undergo a function check.Before replacement, ensure that spare parts are correctly stored, i.e. in particular, protected againstmoisture. Defective electronic components and assemblies must be suitably packed when dispatched forrepair, i.e. in particular, protected against moisture and impact and wrapped in antistatic foil if necessary.

Work with laser devicesWhen working with laser equipment, always wear special laser-protection goggles ⇒ eye injury throughstrongly concentrated beam.Laser devices must be equipped, in accordance with their class and usage, with protective devices forensuring safe operation.For conducting light-beam procedures and measurement work, only the following laser devices may beused:• Laser devices in classes 1, 2 or 3A.• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700

nm), a maximum output of 5 mW, and in which the beam axis and surface have been designed insuch a way as to prevent any risk to the eyes.

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1.5 Fluids and lubricants, fire prevention and environmentalprotection

Fire preventionCorrect fuel or oil leaks immediately. Quantities of oil or fuel on hot components can cause fires – there‐fore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricantslying on or near the assembly or plant. Do not store inflammable material near the assembly or plant.Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.When starting the engine with an external power source, connect the ground lead last and remove it first.To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source tothe ground lead of the engine or to the ground terminal of the starter.Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully withits handling.

NoiseNoise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicatingdanger are drowned.At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors.

Environmental protection and disposalModification or removal of mechanical or electronic components or the installation of additional compo‐nents as well as the execution of calibration processes that might affect the emission characteristics ofthe engine are prohibited by emission regulations. Emission control units/systems may only be main‐tained, exchanged or repaired if the components used for this purpose are approved by MTU. Noncom‐pliance with these guidelines might represent a violation of the Clean Air Act and could involve the termi‐nation of the operating license by the emission authorities. MTU does not accept any liability for viola‐tions of the emission regulations. MTU will provide assistance and advice if emission-relevant compo‐nents are intended to be modified. The MTU Maintenance Schedules ensure the reliability and perform‐ance of MTU engines and must be complied with over the entire life cycle of the engine.Only fuels of the specified quality required to achieve emission limits must be used.Dispose of used fluids, lubricants and filters in accordance with local regulations.Batteries can be returned within the EU to MTU FN / MTU Onsite Energy free of charge for correct recy‐cling/disposal.

Fluids and lubricantsUse only fluids and lubricants that have been tested and approved by MTU.Fluids and lubricants must be kept in suitable, correctly labeled containers. When using fluids, lubricantsand other chemical substances, follow the safety instructions that apply to the product. Take special carewhen using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and donot smoke.

Used oilUsed oil contains combustion residue harmful to health.Rub your hands with skin protection cream.Wash your hands after contact with used oil.

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Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not

inhale lead vapors.• Prevent the buildup of white powder of lead.• Switch on fume extraction system.• After coming into contact with lead or lead-containing materials, wash your hands!

Compressed airWhen working with compressed air, safety precautions must be constantly observed:• Pay special attention to the pressure level in the compressed air network and pressure vessel!• Assemblies or plants to be connected must either be designed for this pressure, or, if the permitted

pressure for the connecting elements is lower than the pressure required, a pressure reducing valveand safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.• Always wear protective goggles when blowing off tools or extracting chips.• Provide the mouthpiece of the air nozzle with a protective disk (e.g. made of rubber).• First shut off compressed air lines before compressed air equipment is disconnected from the supply

line, or before equipment or tool is to be replaced.• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of

containers, results in a risk of explosion!• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for

drying purposes or to check for leaks, results in a risk of bursting!• Carry out the leak check as specified.

Painting• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐

sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.• No naked flames!• No smoking!• Observe all fire-prevention regulations!• Always wear a mask providing protection against paint and solvent vapors!

Liquid nitrogen• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.• Avoid body contact (eyes, hands).• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask!• Make sure that working area is well ventilated.• Take great care not to subject containers, fittings and tools to impact or shock.

Acids/alkaline solutions• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective

clothing.• If acids or alkalis are spilled onto clothing, remove the affected clothing immediately!• Rinse injured parts of the body thoroughly with clean water!• Rinse eyes immediately with eyedrops or clean mains water!

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1.6 Conventions for safety instructions in the text

DANGER In the event of immediate danger.Consequences: Death or serious injury• Remedial action

WARNING In the event of potentially dangerous situations.Consequences: Death or serious injury• Remedial action

CAUTION In the event of dangerous situations.Consequences: Minor injury or material damage• Remedial action

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard whichbegin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions1. Read and familiarize yourself with all safety notices before starting up or repairing the product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 Product Summary2.1 Product description

Description of the engine

EngineThe engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from drivingend), with direct injection, exhaust turbocharging and intercooling.The engine is monitored by an engine control and monitoring system.Monitoring in the engine room is carried out by the engine control and monitoring unit.

Fuel systemElectronically controlled unit injection pumps with jacketed HP lines.The electronic control unit controls• Injection start• Injection quantity

Exhaust systemThe exhaust system is equipped with triple-walled, water-cooled exhaust lines.The triple-walled design permits• Low surface temperature,• Reduced amount of heat to be dissipated by the coolant• Absolute gas-tightness.

TurbochargingSequential turbocharging with intercooling (turbochargers can be cut in/out during operation).

Cooling systemEngine cooled by split-circuit cooling system with plate-core heat exchanger.

Service blockThe service components are mounted at the auxiliary PTO end.The arrangement facilitates easy access for maintenance operations.Service-components:• Raw water pump, coolant pump• Fuel duplex filter, switchable• Lube-oil multiple filter, switchable• Centrifugal lube oil filter• Coolant expansion tank

Electronic systemElectronic control and monitoring system with integrated safety and test system, providing interfaces toRemote Control System (RCS) and Monitoring and Control System (MCS).

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Electronic Engine Control Unit (ECU)Functions:• Engine speed control with fuel and speed limitation dependent on engine state and operating condi‐

tions;• Control of sequential turbocharging;• Data processing logistics for analog and binary signals;• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;• RS 232 interface for connection of MTU dialog unit.

Electronic Engine Monitoring Unit (EMU), optionalFunctions:• Data processing logistics for analog and binary signals;• Interface for data transfer to CAN field bus for remote control and ship-side monitoring.

Electronic Gear Control Unit (GCU), ship-side wall-mountingFunctions:• Date processing logistics for gear coupling control;• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitor‐

ing.

Monitoring in engine roomEngine control and monitoring unit (LOP)Functions:• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when

limits are violated;• Pushbuttons for menu control and dimming unit;• Combined control and display elements for local engine/gear control;• Flashing light and horn for summary alarm in engine room;• Interface to CAN field bus for connected, communicating monitoring system components.

SOLAS – Fire protection specifications

All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standardMTN5233.All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standardMTN5233.

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Fuel system covers


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Lube oil system covers


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Special unions

The following types of union are spray-proof in case of leakage even without covers and have been con‐firmed as being SOLAS-compliant by GL and DNV.

Plug-in pipe unionDesign precludes lateral spray as the parting line is shielded by the sleeve (4).Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring(3).The union is confirmed as being SOLAS-compliant by DNV and GL.

Plugs and sensorsScrew-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,or an O-ring (ISO).The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (2).The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not underpressure.


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High-pressure unions

1 Jacketed pipe2 HP line3 O-ring4 Union nut5 Recess for O-ring6 Thrust ring7 Leakage overflow bore

8 Thrust ring9 Union nut

10 Union nut11 Connecting piece12 Snap ring13 Thrust ring14 Shims

15 Union nut16 Thrust ring17 External pipe of HP line18 Internal pipe of HP line19 Spherical sealing area20 Leak fuel connection

The HP fuel line is sealed by the thrust ring (8).If leakage in the area of the thrust ring (8) or the HP line (5) occurs, the emerging fuel is routed to theleakage chamber.Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The leakage chamberis sealed toward the outside by the O-rings (3).This prevents leaking fuel from escaping.The union is confirmed as being SOLAS-compliant by DNV and GL.


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Shielding of fuel filters and lube-oil filters

Shielding with plastic ring

The plastic ring (1) precludes lateral spray.The fluid is diverted to the catch basin whereby the pressure is greatly reduced.

Shielding by structural overhang

The overhang (1) prevents lateral spray.The fluid is diverted to the catch basin whereby the pressure is greatly reduced.


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2.2 Series 2000 M40A/B - M41A/B

Engine – Overview of functional groups

010 Crankcase and externallymounted components

020 Gear train030 Crank drive040 Cylinder head050 Valve gear070 Fuel system (high pres‐

sure)

080 Fuel system (low pres‐sure)

100 Exhaust turbocharger110 Intercooler120 Air intake/air supply140 Exhaust system170 Starting equipment

180 Lube oil system/lube oilcircuit

200 Coolant circuit230 Mounting/support250 PTO systems, driving end

and free end500 Monitoring, control and

regulation system

Engine model designationKey to the engine model designations 8/12/16V 2000 M40A/B - M41A/B• 8/12/16 = Number of cylinders• V = Cylinder arrangement• 2000 = Series• M4 = Application segment• 0/1 = Design index• A/B = Special features


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2.3 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end ofthe engine.Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end2 Right engine side

3 KS = Driving end4 Left engine side


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2.4 Engine – Main dimensions

Engine – Main dimensions

Engine model Length (A) Width (B) Height (C)8V 2000 M40A / M40B approx. 2005 mm approx. 1280 mm approx. 1315 mm12V 2000 M40A / M40B /M41A /M41B

approx. 2106 mm approx. 1398 mm approx. 1291 mm

16V 2000 M40A / M40B /M41A /M41B

approx. 2815 mm approx. 1425 mm approx. 1291 mm


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2.5 Firing order

Firing order8V A1-B4-A4-A2-B3-A3-B2-B112 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B616 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7


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2.6 Technical Data2.6.1 8V 2000 M40A engine data: engine-mounted heat exchanger, reference

conditions: 25 °C intake air temperature

Explanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop power

A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated without changes (e.g. of power setting)N Not yet defined value- Not applicable

X Applicable

REFERENCE CONDITIONSEngine model 8V 2000

M40AApplication group 3BIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)Number of cylinders 8Engine rated speed A rpm 1500Continuous power ISO 3046 (10% overload capability) (design power DIN6280, ISO 8528)

A kW 385

GENERAL CONDITIONS (for maximum power)Number of cylinders 8Intake air depression (new filter) A mbar 15Intake air depression, max. L mbar 50

MODEL-RELATED DATA (basic design)Number of cylinders 8Cylinder configuration: V angle Degrees 90Bore mm 130Stroke mm 150Cylinder displacement liter 1.99Total displacement liter 15.92Number of inlet valves per cylinder 2Number of exhaust valves per cylinder 2


TIM

-ID: 0

0000

1098

2 - 0

01

RAW WATER CIRCUIT (open circuit)Number of cylinders 8Raw water pump: Inlet pressure, min. L bar -0.2Raw water pump: Inlet pressure, max. L bar +0.5Pressure loss in external raw water system, max. L bar 1.0

LUBE OIL SYSTEMNumber of cylinders 8Lube-oil operating temperature before engine, from R °C 70Lube oil operating temperature before engine, to R °C 75Lube oil operating pressure before engine, from R bar 4.8Lube oil operating pressure before engine, to R bar 5.3Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0

FUEL SYSTEMNumber of cylinders 8Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.3Fuel pressure at supply connection to engine, min. (when engine is run‐ning)

L bar -0.3

Fuel pressure at engine supply connection, max. (when engine is starting) L bar +0.5Fuel supply flow, max. R liter/min 1.3

GENERAL OPERATING DATANumber of cylinders 8Firing speed, from R rpm 100Firing speed, to R rpm 120

STARTING (electric)Number of cylinders 8Starter, rated voltage (standard design) R V= 24

STARTING SYSTEM (with air/hydraulic starter motor)Number of cylinders 8Starting air pressure before starter motor, min. R bar 18*Starting air pressure before starter motor, max. R bar 30


TIM

-ID: 0

0000

1098

2 - 0

01

CAPACITIESNumber of cylinders 8Engine coolant, engine-side (with cooler) R liter 70Engine oil at initial filling (standard oil system) (Option: max. operating incli‐nations)

R liter 65

Oil change quantity, max. (standard oil system) (Option: max. operating in‐clinations)

R liter 60

Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐erating inclinations)

L liter 45

Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐erating inclinations)

L liter 55

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 8Engine dry weight (with attached standard accessories, without coupling) R kg 1790

ACOUSTICSNumber of cylinders 8Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐tance, ISO 6798)

R db(A) 105

Engine surface noise with attenuated intake noise (filter), DL, (free-fieldsound pressure level Lp, 1m distance, ISO 6798)

R db(A) 102


TIM

-ID: 0

0000

1098

2 - 0

01

2.6.2 8V 2000 M40A engine data: separate heat exchanger, reference conditions:25 °C intake air temperature



X Applicable




A kW 385




TIM

-ID: 0

0000

1098

6 - 0

01



L bar -0.3

Fuel pressure at engine supply connection, max. (when engine is starting) L bar +0.5Fuel supply flow, max. R liter/min 10




CAPACITIESNumber of cylinders 8Engine oil at initial filling (standard oil system) (Option: max. operating incli‐nations)

R liter 65


R liter 60


L liter 45


L liter 55



TIM

-ID: 0

0000

1098

6 - 0

01

ACOUSTICSNumber of cylinders 8Exhaust noise, unsilenced, DL, (free-field sound pressure level Lp, 1m dis‐tance, ISO 6798)

R db(A) 105


R db(A) 102


TIM

-ID: 0

0000

1098

6 - 0

01

2.6.3 8V 2000 M40B engine data, engine-mounted heat exchanger, referencecondition: 25 °C intake air temperature



X Applicable


M40BApplication group 3BIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site altitude above sea level m 100


A kW 400




TIM

-ID: 0

0000

1100

3 - 0

01




L bar -0.3






TIM

-ID: 0

0000

1100

3 - 0

01

CAPACITIESNumber of cylinders 8Engine coolant, engine-side (with cooler) R liter 70*Engine oil at initial filling (standard oil system) (Option: max. operating incli‐nations)

R liter 65


R liter 60


L liter 45


L liter 55



R db(A) 105


R db(A) 103


TIM

-ID: 0

0000

1100

3 - 0

01

2.6.4 8V 2000 M40B engine data, separate heat exchanger, reference condition: 25°C intake air temperature



X Applicable




A kW 400




TIM

-ID: 0

0000

1100

5 - 0

01



L bar +0.3






R liter 65


R liter 60


L liter 45


L liter 55



TIM

-ID: 0

0000

1100

5 - 0

01


R db(A) 105


R db(A) 103


TIM

-ID: 0

0000

1100

5 - 0

01

2.6.5 12V 2000 M40A engine data: Engine-mounted heat exchanger, referenceconditions: 45 °C intake air temperature

Explanation:CP Ref. value: Continuous power (CP)

FSP Ref. value: Fuel stop power (FSP)A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power setting)N Not yet defined value- Not applicable

X Applicable

REFERENCE CONDITIONSEngine model 12V

2000M40A

Application group 3BIntake air temperature °C 45Raw-water inlet temperature °C 32Barometric pressure mbar 1000Site altitude above sea level m 100


A kW 575


MODEL-RELATED DATA (basic design)Number of cylinders 12Cylinder configuration: V angle Degrees 90Bore mm 130Stroke mm 150Cylinder displacement liter 1.99Total displacement liter 23.88Number of inlet valves, per cylinder 2Number of exhaust valves, per cylinder 2


TIM

-ID: 0

0000

0295

9 - 0

01

RAW WATER CIRCUIT (open circuit)Number of cylinders 12Raw water pump: inlet pressure, min. L bar -0.2Raw water pump: inlet pressure, max. L bar +0.5Pressure loss in external raw water system, max. L bar 1.0

LUBE OIL SYSTEMNumber of cylinders 12Lube oil temperature before engine, from R °C 73Lube oil temperature before engine, to R °C 78Lube oil operating pressure before engine, from R bar 7.5Lube oil operating pressure before engine, to R bar 8.5Lube oil operating pressure, low idle (meas. point: before engine) R bar 3.5

FUEL SYSTEMNumber of cylinders 12Fuel pressure at supply connection on engine, min. (when engine is start‐ing)

L bar -0.3

Fuel pressure at supply connection on engine, min. (when engine is run‐ning)

L bar -0.3

Fuel pressure at supply connection on engine, max. (when engine is start‐ing)

L bar +0.5

Fuel supply flow, max. R liter/min 2.7


STARTING (electric)Number of cylinders 12Rated starter voltage (standard design) R V= 24

STARTING (pneumatic starter)Number of cylinders 12Starting-air pressure before starter motor, min. R bar 21Starting-air pressure before starter motor, max. R bar 30


TIM

-ID: 0

0000

0295

9 - 0

01

CAPACITIESNumber of cylinders 12Engine coolant capacity (with cooling equipment) R liter 110Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ing inclinations)

R liter 105


R liter 98


L liter 73


L liter 88


ACOUSTICSNumber of cylinders 12Exhaust noise, unsilenced, CP, (free-field sound pressure level Lp, 1m dis‐tance, ISO 6798)

R db(A) 111

Engine surface noise with attenuated intake noise (filter), CP (free-fieldsound pressure level Lp, 1m distance, ISO 6798)

R db(A) 99


TIM

-ID: 0

0000

0295

9 - 0

01

2.6.6 12V 2000 M40A engine data: Engine-mounted heat exchanger, referenceconditions: 25 °C intake air temperature



X Applicable


2000M40A



A kW 575




TIM

-ID: 0

0000

0298

4 - 0

01

RAW WATER CIRCUIT (open circuit)Number of cylinders 12Raw water pump: inlet pressure, min. L bar -0.2Raw water pump: inlet pressure, max. L bar +0.5Pressure loss in external raw water system, max. L bar 1.0



L bar -0.3


L bar -0.3


L bar +0.5

Fuel supply flow, max. R liter/min 2.6





TIM

-ID: 0

0000

0298

4 - 0

01

CAPACITIESNumber of cylinders 12Engine coolant capacity (with cooling equipment) R liter 110Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ing inclinations)

R liter 105


R liter 98


L liter 73


L liter 88



R db(A) 111


R db(A) 99


TIM

-ID: 0

0000

0298

4 - 0

01

2.6.7 12V 2000 M40A engine data: Separate heat exchanger, reference conditions:25 °C intake air temperature



X Applicable


2000M40A



A kW 575




TIM

-ID: 0

0000

0300

4 - 0

01



L bar -0.3


L bar -0.3


L bar +0.5

Fuel supply flow, max. R liter/min 21




CAPACITIESNumber of cylinders 12Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ing inclinations)

R liter 105


R liter 98


L liter 73


L liter 88


TIM

-ID: 0

0000

0300

4 - 0

01



R db(A) 111


R db(A) 99


TIM

-ID: 0

0000

0300

4 - 0

01

2.6.8 12V 2000 M40A engine data: Separate heat exchanger, reference conditions:45 °C intake air temperature



X Applicable


2000M40A



A kW 575




TIM

-ID: 0

0000

0301

9 - 0

01



L bar -0.3


L bar -0.3


L bar +0.5

Fuel supply flow, max. R liter/min 21




CAPACITIESNumber of cylinders 12Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ing inclinations)

R liter 105


R liter 98


L liter 73


L liter 88


TIM

-ID: 0

0000

0301

9 - 0

01



R db(A) 111


R db(A) 99


TIM

-ID: 0

0000

0301

9 - 0

01

2.6.9 16V 2000 M40A engine data: engine-mounted heat exchanger, referenceconditions: 25 °C intake air temperature



X Applicable




A kW 770




TIM

-ID: 0

0000

1099

4 - 0

01


LUBE OIL SYSTEMNumber of cylinders 16Lube-oil operating temperature before engine, from R °C 75Lube oil operating temperature before engine, to R °C 80Lube oil operating pressure before engine, from R bar 6.0Lube oil operating pressure before engine, to R bar 7.0


L bar -0.3






TIM

-ID: 0

0000

1099

4 - 0

01


R liter 134


R liter 127


L liter 97


L liter 117



R db(A) 109


R db(A) 107


TIM

-ID: 0

0000

1099

4 - 0

01

2.6.10 16V 2000 M40A engine data: engine-mounted heat exchanger, referenceconditions: 45 °C intake air temperature



X Applicable




A kW 770




TIM

-ID: 0

0000

1098

9 - 0

01




L bar -0.3






TIM

-ID: 0

0000

1098

9 - 0

01


R liter 134


R liter 127


L liter 97


L liter 117



R db(A) 109


R db(A) 107


TIM

-ID: 0

0000

1098

9 - 0

01




X Applicable




A kW 770




TIM

-ID: 0

0000

1100

0 - 0

01



L bar -0.3






R liter 134


R liter 127


L liter 97


L liter 117



TIM

-ID: 0

0000

1100

0 - 0

01


R db(A) 109


R db(A) 107


TIM

-ID: 0

0000

1100

0 - 0

01




X Applicable




A kW 770




TIM

-ID: 0

0000

1099

7 - 0

01



L bar -0.3






R liter 134


R liter 127


L liter 97


L liter 117



TIM

-ID: 0

0000

1099

7 - 0

01


R db(A) 109


R db(A) 107


TIM

-ID: 0

0000

1099

7 - 0

01




X Applicable




A kW 930




TIM

-ID: 0

0000

1100

8 - 0

01




L bar -0.3






TIM

-ID: 0

0000

1100

8 - 0

01


R liter 134


R liter 127


L liter 97


L liter 117



R db(A) 111


R db(A) 107


TIM

-ID: 0

0000

1100

8 - 0

01




X Applicable




A kW 930




TIM

-ID: 0

0000

1101

3 - 0

01




L bar -0.3






TIM

-ID: 0

0000

1101

3 - 0

01


R liter 134


R liter 127


L liter 97


L liter 117



R db(A) 111


R db(A) 107


TIM

-ID: 0

0000

1101

3 - 0

01

2.6.15 16V 2000 M40B engine data, separate heat exchanger, reference condition:45 °C intake air temperature



X Applicable




A kW 930




TIM

-ID: 0

0000

1101

8 - 0

01



L bar -0.3






R liter 134


R liter 127


L liter 97


L liter 117



TIM

-ID: 0

0000

1101

8 - 0

01


R db(A) 111


R db(A) 107


TIM

-ID: 0

0000

1101

8 - 0

01

2.6.16 16V 2000 M40B engine data, separate heat exchanger, reference condition:25 °C intake air temperature



X Applicable




A kW 930




TIM

-ID: 0

0000

1102

2 - 0

01



L bar -0.3






R liter 134


R liter 127


L liter 97


L liter 117



TIM

-ID: 0

0000

1102

2 - 0

01


R db(A) 111


R db(A) 107


TIM

-ID: 0

0000

1102

2 - 0

01

2.6.17 ENGINE DATA 12V 2000M41A/B


A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated without change (e.g. of power settings).N Not yet defined value- Not applicable

X Applicable

Engine model 12V2000M41A

heat ex‐changerinstalled

12V2000M41A

heat ex‐changerseparate

12V2000M41B


12V2000M41B


Application group 3B 3B 3B 3BIntake air temperature °C 25 25 25 25Charge-air coolant temperature °C - - - -Raw-water inlet temperature °C 25 25 25 25Barometric pressure mbar 1000 1000 1000 1000Site altitude above sea level m 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)Number of cylinders 12 12 12 12Rated engine speed A rpm 1500 1500 1800 1800Continuous power ISO 3046 (10% over‐load capability) (design power DIN 6280,ISO 8528)

A kW 575 575 695 695

GENERAL CONDITIONS (for maximum power)Number of cylinders 12 12 12 12Intake depression (new filter) A mbar 15 15 15 15Intake depression, max. L mbar 50 50 50 50

MODEL-RELATED DATA (basic design)Number of cylinders 12 12 12 12Cylinder arrangement: V-angle Degrees

(°)90 90 90 90

Bore mm 130 130 130 130Stroke mm 150 150 150 150Cylinder displacement Liters 1.99 1.99 1.99 1.99Total displacement Liters 23.88 23.88 23.88 23.88


TIM

-ID: 0

0000

1912

2 - 0

01

Number of cylinders 12 12 12 12Number of inlet valves per cylinder 2 2 2 2Number of exhaust valves per cylinder 2 2 2 2

RAW WATER CIRCUIT (open circuit)Number of cylinders 12 12 12 12Raw water pump: Inlet pressure, min. L bar -0.2 - -0.2 -Raw water pump: Inlet pressure, max. L bar +0.5 - +0.5 -Pressure loss in off-engine raw watersystem, max.

L bar 1.0 - 1.0 -

LUBE OIL SYSTEMNumber of cylinders 12 12 12 12Lube oil operating temperature beforeengine, from

R °C 70 75 75 75

Lube oil operating temperature beforeengine, to

R °C 75 85 80 85

Lube oil operating pressure before en‐gine, from

R bar 7.5 7.5 7.5 7.5

Lube oil operating pressure before en‐gine, to

R bar 8.5 8.5 8.5 8.5

Lube oil operating pressure (low idle)(meas. point: before engine)

R bar 3.5 3.5 3.5 3.5

FUEL SYSTEMNumber of cylinders 12 12 12 12Fuel pressure at engine supply connec‐tion, min. (when engine is starting)

L bar -0.3 -0.3 -0.3 -0.3

Fuel pressure at engine supply connec‐tion, min. (during engine operation)

L bar -0.3 -0.3 -0.3 -0.3

Fuel pressure at engine supply connec‐tion (when engine is starting), max.

L bar +0.5 +0.5 +0.5 +0.5

Fuel supply flow rate, max. A liters/min 2.6 21 3.2 26

GENERAL OPERATING DATANumber of cylinders 12 12 12 12Firing speed, from R rpm 100 100 100 100Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)Number of cylinders 12 12 12 12Rated starter voltage (standard design) R V= 24 24 24 24


TIM

-ID: 0

0000

1912

2 - 0

01

STARTING SYSTEM (with compressed air/hydraulic starter motor)Number of cylinders 12 12 12 12Starting-air pressure before starter mo‐tor, min.

R bar 21* 21* 21* 21*

Starting-air pressure before starter, max. R bar 30 30 30 30

FILLING CAPACITIESNumber of cylinders 12 12 12 12Engine coolant, engine side (with cool‐ing system)

R liters 110 - 110 -

Engine oil, total, for initial filling (stand‐ard oil system) (option: max. operatinginclinations)

R liters 105 105 105 105

Oil change quantity, max. (standard oilsystem) (Option: max. operating inclina‐tions)

R liters 98 98 98 98

Oil pan capacity at dipstick mark “min.”(standard oil system) (Option: max. op‐erating inclinations)

L liters 73 73 73 73

Oil pan capacity at dipstick mark “max.”(standard oil system) (Option: max. op‐erating inclinations)

L liters 88 88 88 88

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 12 12 12 12Dry engine weight (with standard acces‐sories, without coupling)

R kg 2600 2600 2600 2600

NOISENumber of cylinders 12 12 12 12Exhaust noise, unsilenced, DL, (free-field sound-pressure level Lp, 1m dis‐tance, ISO 6798)

R dB(A) 104 104 103 103

Engine surface noise with attenuated in‐take noise (filter) - BL (free-field sound-pressure level Lp, 1 m distance, ISO6798, +2dB(A) tolerance)

R dB(A) 99 99 100 100


TIM

-ID: 0

0000

1912

2 - 0

01

2.6.18 ENGINE DATA 16V 2000M41A/B


A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated without change (e.g. of power settings).N Not yet defined value- Not applicable

X Applicable

Engine model 16V2000M41A


16V2000M41A


16V2000M41B


16V2000M41B


Application group 3B 3B 3B 3BIntake air temperature °C 25 25 25 25Charge-air coolant temperature °C - - - -Raw-water inlet temperature °C 25 25 25 25Barometric pressure mbar 1000 1000 1000 1000Site altitude above sea level m 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)Number of cylinders 16 16 16 16Rated engine speed A rpm 1500 1500 1800 1800Continuous power ISO 3046 (10% over‐load capability) (design power DIN 6280,ISO 8528)

A kW 770 770 930 930

GENERAL CONDITIONS (for maximum power)Number of cylinders 16 16 16 16Intake depression (new filter) A mbar 15 15 15 15Intake depression, max. L mbar 50 50 50 50

MODEL-RELATED DATA (basic design)Number of cylinders 16 16 16 16Cylinder arrangement: V-angle Degrees

(°)90 90 90 90

Bore mm 130 130 130 130Stroke mm 150 150 150 150Cylinder displacement liters 1.99 1.99 1.99 1.99Total displacement liters 31.84 31.84 31.84 31.84


TIM

-ID: 0

0000

1912

4 - 0

01

Number of cylinders 16 16 16 16Number of inlet valves per cylinder 2 2 2 2Number of exhaust valves per cylinder 2 2 2 2

RAW WATER CIRCUIT (open circuit)Number of cylinders 16 16 16 16Raw water pump: Inlet pressure, min. L bar -0.2 - -0.2 -Raw water pump: Inlet pressure, max. L bar +0.5 - +0.5 -Pressure loss in off-engine raw watersystem, max.

L bar 1.0 - 1.0 -

LUBE OIL SYSTEMNumber of cylinders 16 16 16 16Lube oil operating temperature beforeengine, from

R °C 75 75 80 80

Lube oil operating temperature beforeengine, to

R °C 80 80 85 85

Lube oil operating pressure before en‐gine, from

R bar 6.0 6.0 6.0 6.0

Lube oil operating pressure before en‐gine, to

R bar 7.0 7.0 7.0 7.0

Lube oil operating pressure (low idle)(meas. point: before engine)

R bar N N N N

FUEL SYSTEMNumber of cylinders 16 16 16 16Fuel pressure at engine supply connec‐tion, min. (when engine is starting)

L bar -0.3 -0.3 -0.3 -0.3

Fuel pressure at engine supply connec‐tion, min. (during engine operation)

L bar -0.3 -0.3 -0.3 -0.3

Fuel pressure at engine supply connec‐tion (when engine is starting), max.

L bar +0.5 +0.5 +0.5 +0.5

Fuel supply flow rate, max. A liters/min 3.4 20 4.2 24

GENERAL OPERATING DATANumber of cylinders 16 16 16 16Firing speed, from R rpm 100 100 100 100Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)Number of cylinders 16 16 16 16Rated starter voltage (standard design) R V= 24 24 24 24


TIM

-ID: 0

0000

1912

4 - 0

01

STARTING SYSTEM (with compressed air/hydraulic starter motor)Number of cylinders 16 16 16 16Starting-air pressure before starter mo‐tor, min.

R bar 24* 24* 24* 24*

Starting-air pressure before starter, max. R bar 30 30 30 30

FILLING CAPACITIESNumber of cylinders 16 16 16 16Engine coolant, engine side (with cool‐ing system)

R liters 160 - 160 -

Engine oil, total, for initial filling (stand‐ard oil system) (option: max. operatinginclinations)

R liters 134 134 134 134

Oil change quantity, max. (standard oilsystem) (Option: max. operating inclina‐tions)

R liters 127 127 127 127

Oil pan capacity at dipstick mark “min.”(standard oil system) (Option: max. op‐erating inclinations)

L liters 97 97 97 97

Oil pan capacity at dipstick mark “max.”(standard oil system) (Option: max. op‐erating inclinations)

L liters 117 117 117 117

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 16 16 16 16Dry engine weight (with standard acces‐sories, without coupling)

R kg 3200 3200 3200 3200

NOISENumber of cylinders 16 16 16 16Exhaust noise, unsilenced, DL, (free-field sound-pressure level Lp, 1m dis‐tance, ISO 6798)

R dB(A) 109 109 111 111

Engine surface noise with attenuated in‐take noise (filter) - BL (free-field sound-pressure level Lp, 1 m distance, ISO6798, +2dB(A) tolerance)

R dB(A) 107 107 107 107


TIM

-ID: 0

0000

1912

4 - 0

01

3 Operation3.1 LOP – Controls

LOP – Controls

Item Color Lettering Meaning / Function1 White F1 Function keys to control the human-machine interface.

Functions vary and are displayed on the LCD screen.2 White F23 White F34 White F45 White F56 White ALARM AC‐

KNOWLEDGEPressing the key the first time stops alarm signalization.Pressing the button a second time acknowledges an activealarm.LED (spot) lights up when an alarm is active.

7 White DIMMER ↑ Holding down the key increases LCD background illumina‐tion.

MS150031/03E 2011-10 | Operation | 85

TIM

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0000

0885

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03

Item Color Lettering Meaning / Function8 White DIMMER ↓ Holding down the key decreases LCD background illumina‐

tion.9 White LAMP TEST Pressing the button initiates lamp test.10 Red TEST OVER‐

SPEEDPressing the button initiates overspeed test.LED (spot) lights up as long as the overspeed test is run‐ning.

11 Green (none) (none)12 Green (none) (none)13 Green (none) (none)14 White ENGINE SPEED

INCREASEEngine speed is increased as long as the button is helddown.

15 White ENGINE SPEEDDECREASE

Engine speed is decreased as long as the button is helddown.

16 Green READY FOR OP‐ERATION

Pressing the switch causes changeover between “Not readyfor operation” and “Ready for operation” status.LED (spot) lights up at "Ready for operation" switch posi‐tion.

17 Green LOCAL OPERA‐TION

Pressing the switch activates changeover between localand remote control mode.LED (spot) lights up when local mode is active.

18 White START Pressing the pushbutton initiates the automatic engine startsequence.LED (spot) lights up as long as the starting procedure isrunning.

19 White STOP Pressing the button initiates automatic engine stopping pro‐cedure.Spot LED lit when stop signal is applied (also from remotecontrol system).

20 Red EMERGENCYSTOP

Pressing the pushbutton initiates an immediate emergencyengine stop.LED (spot) flashes once the emergency stop has been trip‐ped and until the alarm has been acknowledged.

86 | Operation | MS150031/03E 2011-10

TIM

-ID: 0

0000

0885

6 - 0

03

3.2 Putting the engine into operation (out-of-service period > 3months)

Preconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specification (A001061/..) is available.

Putting the engine into operation (out-of-service period > 3 months)Item TaskEngine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/.. ).Lube oil system Check oil level (→ Page 146).Fuel prefilter Prime (→ Page 139).Fuel prefilter, pressuregauge

Align adjustable pointer with position of pressure indicator (→ Page 135).

Fuel system Vent (→ Page 131).Raw-water pump (if locatedabove waterline)

Prime (approx. 3 to 4 liters).

Cooling system If engine is out of service for more than one year, change coolant(→ Page 160).

Cooling system Check coolant level (→ Page 159).Cooling system Preheat coolant with preheating unit.ECU Check plug-in connections (→ Page 176).Engine control system Switch ON.

Press READY FOR OPERATION button (→ Page 85).LOP Press LAMP TEST button (→ Page 85).

MS150031/03E 2011-10 | Operation | 87

TIM

-ID: 0

0000

0220

5 - 0

01

3.3 Putting the engine into operation after scheduled out-of-service period

Preconditions☑ Engine is stopped and starting disabled.

Putting into operationItem TaskLube oil system Check oil level (→ Page 146).Cooling system Check coolant level (→ Page 159).Cooling system Preheat coolant with preheating unit.Fuel prefilter Drain (→ Page 136).Battery-charging generatordrive

Check condition of drive belt (→ Page 166).

Engine control system Switch ON.Press READY FOR OPERATION button (→ Page 85).

LOP Press LAMP TEST button (→ Page 85).

88 | Operation | MS150031/03E 2011-10

TIM

-ID: 0

0000

0268

4 - 0

01

3.4 Starting the engine from LOP

Preconditions☑ Gearbox is disengaged.☑ External start interlock is not activated.☑ Emergency air-shut-off flaps (if provided) are open.

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING Engine noise above 85 dB (A).Risk of damage to hearing!• Wear ear protectors.

Barring the engine (out-of-service period > 1 month)Item TaskEngine Bar with starting system (→ Page 105).

Starting the engine from LOPItem TaskEngine Make sure that engine is in unloaded condition.Engine control system Switch ON.

LOP:• LOCAL OPERATION button is illuminated brightly (local operating

mode is active) (→ Page 85);• CLUTCH NEUTRAL button is illuminated brightly (gearbox is disengag‐

ed) (→ Page 85).LOP Press READY FOR OPERATION button briefly (→ Page 85).

• READY FOR OPERATION button is illuminated brightly.LOP Press START button briefly (→ Page 85).

• START button of the engine concerned is illuminated brightly;• Automatic starting procedure is performed;• Tachometer indicates increasing crankshaft speed;• After the starting procedure is completed, engine is running at idle

speed and START button is reset to basic illumination.

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3.5 Operational checks

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working on a running engine.


Operational checksItem TaskEngine under loadEngine at nominal speed

Visually inspect the engine for leaks and general condition;Check for abnormal noises and vibrations;Check exhaust color (→ Page 96).

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressuregauge is within the limit. (→ Page 135).Drain off water and dirt (→ Page 136)

Intercooler Check drain line for water discharge and obstruction (→ Page 141).Air filter Check signal ring position of service indicator (→ Page 144);

Replace air filter (→ Page 142), if the signal ring is completely visible in theservice indicator control window.

HT coolant pump Check relief bore for oil and coolant discharge and dirt (→ Page 163).Raw-water pump Check relief bore for oil and water discharge and dirt (→ Page 165)

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3.6 Stopping the engine at the LOP

Preconditions☑ Engine is running in local mode.

CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!• Before stopping the engine, operate it at idle speed until operating temperatures decrease and

stable values are indicated.

Stopping the engine at the LOPItem ActionLOP Operate engine at idle speed (→ Page 85).Temperature readings Wait until engine is at operating temperature.LOP Press STOP pushbutton (→ Page 85).

• STOP pushbutton is illuminated;• engine is stopped.

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3.7 Emergency stop from LOP

CAUTION An emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop only in emergency situations.

Emergency stop from LOPItem TaskLOP Open cap of EMERGENCY STOP button (→ Page 85).LOP Press EMERGENCY STOP button.

• Engine is stopped by switching off power supply to ECU;• Engine control is deactivated;• Engines with emergency air-shut-off flaps: Flaps close;• EMERGENCY STOP button flashes.signalization by horn, flash lamp

etc. is released.

After emergency stop from LOPItem TaskLOP Press ALARM ACKNOWLEDGE button (→ Page 85).

• Audible and visual signalization stops.LOP Press ALARM ACKNOWLEDGE button again.

• Power supply to ECU is provided;• Alarm is acknowledged.

Engine Engines with emergency air-shut-off flaps: Flaps open.• Engine is ready for operation.

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3.8 After stopping the engine

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

After stopping the engineItem ActionCoolant circuit Drain coolant (→ Page 161) if:

• freezing temperatures are expected and the engine is to remain out ofservice for an extended period, but engine coolant has no antifreezeadditive;

• the engine room is not heated;• the coolant is not kept at a suitable temperature;• the antifreeze concentration is insufficient for the engine-room tempera‐

ture;• antifreeze concentration is 50 % and engine-room temperature is below

-40 °C.Raw water Drain

• If freezing temperatures are to be expected and the engine is to remainout of service for an extended period.

Engine control system Switch off.Air intake and exhaust sys‐tem

Out-of-service-period > 1 week• Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month• Preserve engine (→ MTU Fluids and Lubricants Specifications

A001061/.. )

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3.9 Plant – Cleaning

Preconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not applied.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Steam jet cleaner - 1Cleaner (Hakupur 312) 30390 1

WARNING Compressed airRisk of injury!• Do not direct compressed-air jet at persons.• Wear protective goggles / safety mask and ear protectors.

WARNING Water jet.Risk of injury and scalding!• Do not direct water jet at persons.• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION Excessive reaction time of cleaning agents on components.Damage to component!• Observe manufacturer's instructions.• Wear protective clothing, gloves, and goggles / safety mask.

Note: There is a risk of damaging sensors with compressed air.

Plant – Cleaning1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐

tection).2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit

carefully and observe the safety precautions.3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.4. Carry out external cleaning as follows:

a) Remove coarse dirt.b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.c) Use the high-pressure jet to remove the loosened dirt.d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet

(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 mmust be observed. The temperature of the cleaning medium must not exceed 80°C.

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4 Maintenance4.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a stand-alone publication.The task numbers in this table provide reference to the maintenance tasks specified in the maintenanceschedule.

TaskW0500 (→ Page 146)W0501 (→ Page 90)W0502 (→ Page 141)W0503 (→ Page 90)W0505 (→ Page 90)W0506 (→ Page 96)W0507 (→ Page 90)W0508 (→ Page 90)W1001 (→ Page 133)W1002 (→ Page 115)W1005 (→ Page 90)W1006 (→ Page 123)W1007 (→ Page 120)W1008 (→ Page 149)W1009 (→ Page 151)W1011 (→ Page 106)W1140 (→ Page 112)W1178 (→ Page 128)

Table 1: Maintenance task reference table [QL1]

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5 Troubleshooting5.1 Troubleshooting

Engine does not turn when starter is actuatedComponent Probable Cause TaskBattery Low or defective Charge or replace (see manufacturer's

documentation).Cable connections defective Check if cable connections are proper‐

ly secured (see manufacturer's docu‐mentation).

Starter (electric) Engine wiring or starter defective Check if cable connections are proper‐ly secured, contact Service.

Starter (compressedair)

Starting-air pressure not available Check firm seating of connections,check starting-air pressure and mainvalve of compressed-air system. Con‐tact Service.

Engine wiring Defective Check (→ Page 172).LOP Secure seating of assemblies or con‐

nectors not providedPerform visual inspection(→ Page 181).

ECU Plug-in connections are loose Check plug-in connections(→ Page 176).

Engine Running gear blocked (engine cannotbe barred manually)

Contact Service.

Start-interlock limitswitch

Limit switch not installed Check limit switch (→ Page 175).Limit switch defectiveWiring defective Check wiring (→ Page 172).

Engine turns but does not fireComponent Probable Cause TaskStarter Poor rotation by starter: Battery low or

defectiveCharge or replace battery (see manu‐facturer's documentation).

Engine wiring Defective Check (→ Page 172).Fuel system Not vented Vent fuel system (→ Page 131).ECU Defective Contact Service.

Engine fires unevenlyComponent Probable Cause TaskFuel injection equip‐ment

Injector defective Replace (→ Page 123).Injection pump defective Replace (→ Page 120).

Engine wiring Defective Check (→ Page 172).Fuel system Not vented Vent fuel system (→ Page 131).ECU Defective Contact Service.

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Engine does not reach nominal speedComponent Probable Cause TaskFuel supply Fuel supply shut off Open shut-off valve before fuel prefilter

completely.Fuel prefilter clogged Replace (→ Page 139).Fuel filter clogged Replace (→ Page 133).

Air supply Air filter clogged Check signal ring position of service in‐dicator (→ Page 144).

Fuel injection equip‐ment


Engine wiring Defective Check (→ Page 172).Engine Overloaded Contact Service.

Engine speed not steadyComponent Probable Cause TaskFuel injection equip‐ment


Speed sensor Defective Contact Service.Fuel system Not vented Vent fuel system (→ Page 131).ECU Defective Contact Service.

Charge-air temperature too highComponent Probable Cause TaskEngine coolant Incorrect coolant concentration Check (MTU test kit).Intercooler Contaminated Contact Service.Engine room Air-intake temperature too high Check fans

Check air supply / ventilation ducts.

Charge-air pressure too lowComponent Probable Cause TaskAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 144).Intercooler Contaminated Contact Service.Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercoolerComponent Probable Cause TaskIntercooler Leaking, major coolant discharge. Contact Service.

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Exhaust gas blackComponent Probable Cause TaskAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 144).Fuel injection equip‐ment


Engine Overloaded Contact Service.

Exhaust gas blueComponent Probable Cause TaskEngine oil Too much oil in engine Drain engine oil (→ Page 147).

Oil separator or oil preseparator ofcrankcase breather clogged

Replace (→ Page 113).

Exhaust turbochargerCylinder headPiston ringsCylinder liner

Defective Contact Service.

Exhaust gas whiteComponent Probable Cause TaskEngine Not at operating temperature Run engine to reach operating temper‐

ature.Fuel system Water in fuel Check fuel system on fuel prefilter;

Drain fuel prefilter (→ Page 136).Intercooler Leaking Contact Service.


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5.2 LOP alarms

LOPAt the LOP, alarm texts and measuring-point messages are indicated on the DIS. Explanation of the dis‐played texts can be gathered by pressing the help key on the touch screen. Alarms can also be causedby defective sensors / actuators. If troubleshooting in accordance with the following table is not success‐ful, contact Service to have the sensors / actuators checked and, if required, replaced.

Display text Meaning TaskAL RCS Speed De‐mand Defect

No speed demand signal 1. Check speed demand source sys‐tem (e. g. from automatic on-boardnetwork).

2. Check LOP visually (→ Page 181);3. Perform LOP test procedures

(→ Page 183).4. Check ECU plug-in connections

(→ Page 176).5. Check engine wiring (→ Page 172).

AL Shutdown Expect‐ed

Yellow alarm occurred; Red alarm withengine shutdown will probably follow

1. Start the other gensetas a preventive measure.

2. Determine cause of yellow alarmand rectify.

AL Battery ChargerFail

No battery charging 1. Check power circuit breakers andfuses.

2. Check transistor controllers.AL Press MonitoringFail (EMU)

EMU pressure monitoring failure Contact Service• Have EMU replaced.

AL ECU Defect ECU 4 is defective 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures


(→ Page 176).4. Check engine wiring (→ Page 172).5. Contact Service

• Have ECU checked and re‐placed, if required.

AL Power Amplifier 1Fail

Power amplifier cylinder side A failure 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures





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Display text Meaning TaskAL Power Amplifier 2Fail

Power amplifier cylinder side B failure 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures




AL Override Activat‐ed

Engine safety system not active Status message:• Override activated.

AL Power Fail Con‐trol

Power failure of control system Check power circuit breakers andfuses.

AL Power Fail Moni‐toring

Power failure Check power circuit breakers andfuses.

AL Transistor Output1/2 Fail

One of the ECU transistor outputs(TAA1 or TAA2) is defective

Contact Service• Have ECU checked and replaced, if

required.AL Transistor Output3/4 Fail

One of the ECU transistor outputs(TAA3 or TAA4) is defective

Contact Service• Have ECU checked and replaced, if

required.AL Water in Fuel Pre‐filter

Water in fuel prefilter Drain fuel prefilter (→ Page 136).

DL 211+A001-A001 Display panel DIS not detected on de‐fault bus

1. Check LOP visually (→ Page 181).2. Perform LOP test procedures



• Have DIS checked and re‐placed, if required.

DL 211+A001-A010 LCU of LOP 1 (PIM No. 21.X+A001-A010) not detected on default bus




• Have MPU 23 of PIM No. 21.X+A001-A010 checked and re‐placed, if required.

DL 211+A001-A020 LMU of LOP 1 (PIM No. 21.X+A001-A020) not detected on default bus






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Display text Meaning TaskDL 211+A003-ECU ECU 4 not detected on default bus 1. Check LOP visually (→ Page 181).

2. Perform LOP test procedures(→ Page 183).

3. Check ECU plug-in connections(→ Page 176).

4. Check engine wiring (→ Page 172).5. Contact Service


DL 211+A004-EMU EMU 1 not detected on default bus 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures



• Have EMU checked and re‐placed, if required.

HI P-Oil Filter Differ‐ence

Excessive oil-pressure difference be‐tween oil-filter inlet and outlet

Replace engine oil filter (→ Page 149).

MG Check Start In‐terlocks

Start conditions not fulfilled Check start conditions and fulfill if nec‐essary.

RL 211+A001-A001 DIS not detected on redundant bus 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures

(→ Page 183).3. Contact Service

• Have DIS checked and re‐placed, if required.

RL 211+A001-A010 LCU of LOP 1 (PIM No. 21.X+A001-A010) not detected on redundant bus




RL 211+A001-A020 LMU of LOP 1 (PIM No. 21.X+A001-A020) not detected on redundant bus




RL 211+A003-ECU ECU 4 not detected on redundant bus 1. Check LOP visually (→ Page 181).2. Perform LOP test procedures





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Display text Meaning TaskRL 211+A004-EMU EMU 1 not detected on redundant bus 1. Check LOP visually (→ Page 181).

2. Perform LOP test procedures(→ Page 183).

3. Contact Service• Have EMU checked and re‐

placed, if required.SS Safety SystemFail (EMU)

Safety system has detected EMU fail‐ure

Contact Service.

SS Power ReductionActive

Safety system has requested powerreduction

1. Determine cause of automaticpower reduction.

2. Note further alarms / indications ondisplay.

3. Contact Service.SS Emergency Stop Safety system has tripped an emer‐

gency stop1. Determine cause of shutdown and

rectify.2. Note further alarms / indications on

display.SS Emergency StopExt.

Safety system has executed an exter‐nally tripped emergency stop

1. Determine cause of shutdown andrectify.


SS P-Coolant Safety system detects that coolantpressure is too low

Check coolant level and top up if re‐quired (→ Page 159).

SS P-Lube Oil (ECU) Safety system detects that engine-oilpressure is too low

1. Check lube oil level and top up ifrequired (→ Page 146).

2. Contact Service.SS P-Lube Oil (EMU) Safety system detects that engine-oil

pressure is too low1. Check lube oil level and top up if

required (→ Page 146).2. Contact Service.

SS Security ChannelDef EMU

Fault message of safety system Contact Service• Have EMU checked and replaced, if

required.SS SDAF Closed Safety system reports closed emer‐

gency air-shut-off flapsOpen air-shutoff flaps

SS Security Shut‐down

Safety system has tripped a shutdown Determine cause of shutdown and rec‐tify.

SS T-Coolant (ECU) Safety system detects excessive cool‐ant temperature

Reduce power.

SS T-Coolant (EMU) Safety system detects excessive cool‐ant temperature

Reduce power.

SS T-Lube Oil Safety system detects excessive lube-oil temperature

Reduce power.

Stop Activated (EMU) EMU has tripped automatic stop com‐mand due to limit value violation

1. Determine cause of shutdown andrectify.



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Display text Meaning TaskTD P-Lube Oil Different measurement values trans‐

mitted by the two sensors for lube-oilpressure measurement




• Have sensors checked and re‐placed, if required.

TD T-Coolant Different measurement values trans‐mitted by the two sensors for coolanttemperature measurement




• Have sensors checked and re‐placed, if required.

Cylinder Cutout Measuring point "Cylinder Cutout" Status message of 'Cylinder cutout /half of cylinders running' mode in idleoperation.


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6 Task Description6.1 Engine

6.1.1 Engine – Barring manually


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Ratchet F30006212 1Socket F30005655 1

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• before barring or starting the engine, ensure that nobody is in the danger zone.• After working on the engine, check that all protective devices have been reinstalled and all tools

removed from the engine.

Engine – Barring manually1. Remove cover plate (2).2. Attach ratchet with socket to barring tool.3. Rotate crankshaft in engine direction of ro‐

tation. Apart from the normal compressionresistance, there should be no abnormal re‐sistance.

Result: If the resistance exceeds compression re‐sistance, contact Service.

4. For barring-tool removal follow reverse se‐quence of working steps.

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6.1.2 Engine – Barring with starting system

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers 0135315483 1

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• before barring or starting the engine, ensure that nobody is in the danger zone.• After working on the engine, check that all protective devices have been reinstalled and all tools

removed from the engine.

Engine – Barring with startingsystem

1. Disengage the bayonet coupling (4) of con‐nector X4 with connector pliers (2) andwithdraw connector (3) from engine gover‐nor.

2. Bar engine in unloaded condition: PressSTART button.

3. Let the crankshaft rotate until oil pressure isindicated.

4. Engine start is automatically interruptedwhen specified starting period is expired. Ifnecessary, re-start the engine after approx.20 seconds.

5. Plug connector X4 (3) and use connectorpliers (2) to secure the bayonet coupling (4)by turning it clockwise until it latches intoplace.

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6.2 Cylinder Liner6.2.1 Cylinder liner – Endoscopic examination

Preconditions☑ Engine is stopped and starting disabled

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover (→ Page 118).2. Remove injector (→ Page 124).

Positioning crankshaft at BDC1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached

BDC.2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder linerFindings Measure• Thin carbon coating on circumference of carbon scraper ring• Slight localized additive deposits at top edge• Localized smooth areas at bottom edge• Carbon deposits on circumference in clearance between top piston

ring and bottom edge of carbon scraper ring• First signs of marks left by top piston ring• Bright mark on entire circumference• Consistent honing pattern without objections• First signs of marks left by lower cooling bores• Running pattern seems darker

No action required

• Dark areas with even or varying degrees of discoloration• Beginning and end of the discoloration are not sharply defined and

do not cover the entire stroke area• Dark areas in the upper section of the cooling bore, remaining cir‐

cumference without objections• Piston rings without objections

Further endoscopic examina‐tion required as part of main‐tenance work

• On the entire circumference, apart from light areas of discoloration(that do not impair operation) clearly darker stripes that start at thetop piston ring

• Heat discoloration in the direction of stroke and honing pattern dam‐age

• Heat discoloration of piston rings

Cylinder liner must be re‐placed; Service must be con‐tacted

1. Compile endoscopic report using the table.2. Use technical terms for description of the liner surface (→ Page 108).3. Depending on findings:

• Do not take any action or• carry out a further endoscopic examination as part of maintenance work or• contact Service; cylinder liner must be replaced.


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Final steps1. Install injector (→ Page 124).2. Install cylinder head cover (→ Page 118).


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6.2.2 Instructions and comments on endoscopic and visual examination of cylinderliners

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐nation report.

Finding ActionMinor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐

ucts, particles, broken-off burrs). Removed cylinders clearly show such scoringon the running surface under endoscope magnification. Cannot be felt with thefingernail.Findings not critical.

Single scores Clearly visible scores from hard particles. They usually start in the TDC areaand cross through the hone pattern in the direction of stroke.Findings not critical.

Scored area These areas consist of scores of different length and depth next to one anoth‐er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐let/exhaust) along the transverse engine axis.Findings not critical.

Smoothened area Smoothened areas are on the running surface but almost the whole honingpattern is still visible. Smoothened areas appear brighter and more brilliantthan the surrounding running surface.Findings not critical.

Polished area Polished areas are on the running surface and show local removal of the hon‐ing pattern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐perature differences around the liner. It appears rather darker within the honedstructure in contrast to the bright metallic running surface. The honing patternis undisturbed. Discolorations extend in stroke direction and may be interrupt‐ed.Findings not critical.

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves inthe overlap (open) position. They are clearly visible due to the dark color of thehoning groove bottom.This corrosion is not critical unless there are corrosion pittings.

Black lines Black lines are a step towards heat discoloration. They are visible as a cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinders with a number of black lines around the running surface have limitedservice life and should be replaced.


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Finding ActionDiscolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they

run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ringand becoming more visible from the second TDC-ring onwards and less pro‐nounced from TDC-ring 1. The honing pattern is usually no longer visible anddisplays a clearly defined (straight) edge to the undisturbed surface. The dam‐aged surface is usually discolored. The circumferential length varies.Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

Seizures, Seizuremarks

Irregular circumference lengths and depths. Can be caused either by the pis‐ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis‐coloration. Severe, visible scoring.Replace liner.

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐necessary disassembly work, it is recommended that another inspection be carried out after further oper‐ation of the engine.


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6.3 Crankcase Breather6.3.1 Crankcase breather – Oil separator element replacement, diaphragm check

and replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027340 1Engine oilFilter element (→ Spare Parts Catalog)Diaphragm (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)

WARNING Hot oil.Oil can contain combustion residues which are harmful to health.Risk of injury and poisoning!• Wear protective clothing, gloves, and goggles / safety mask.• Avoid contact with skin.• Do not inhale oil vapor.

Replacing oil separator element1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from housing (4).3. Insert new filter element in housing (4).4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm − 2 Nm

6. Replace further oil separator elements in the same way.


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Checking diaphragm1. Remove cover (4).2. Remove spring (5), gasket (2) and dia‐

phragm (3).3. Check diaphragm (3) for damage, fit new

diaphragm if used one is damaged.4. Install diaphragm (3) on housing (1).5. Install new seal (2) and spring (5) together

with cover (4).

6. Use torque wrench to tighten the screws of cover (4) to the specified torque.


Screw Tightening torque (Engine oil) 10 Nm − 2 Nm

7. Check diaphragms in further oil separators in the same way.


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6.3.2 Crankcase breather – Cleaning oil separator element


Special tools, Material, Spare partsDesignation / Use Part No. Qty.FuelGasket (→ Spare Parts Catalog)

WARNING Fuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do not smoke.


Crankcase breather – Cleaning oilseparator element

1. Remove cover (1) from housing (4).2. Remove oil separator (2) and gasket (3).3. Clean oil separator (2) in fuel and blow dry

with compressed air.4. Moisten oil separator (2) with engine oil.5. Place oil separator (2) with new gasket (3)

onto housing (4) and install cover (1).6. Clean further oil separator element in the

same way.


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6.3.3 Crankcase breather – Oil separator replacement, diaphragm check andreplacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027340 1Filter element (→ Spare Parts Catalog)Diaphragm (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)


Replacing filter element of oilseparator

1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from housing (4).3. Insert new filter element into housing (4)

ensuring correct installation position, and fitcover (2) with new O-ring.

4. Tighten screws of cover (2) to specified tightening torque.


Screw Tightening torque 6 Nm + 2 Nm

5. Replace filter elements of further oil separators in the same way.


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Checking diaphragm1. Remove cover (4).2. Take off spring (5), seal (2) and diaphragm

(3).3. Check diaphragm (3) for damage.4. Fit new diaphragm if used one is damaged.5. Mount diaphragm (3) on housing (1).6. Install new seal (2) and spring (5) together

with cover (4).

7. Tighten screws of cover (4) to specified tightening torque.


Screw Tightening torque 6 Nm + 2 Nm

8. Check diaphragms in further oil separators in the same way.


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6.4 Valve Drive6.4.1 Valve clearance – Checking and adjusting

Preconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max. 40 °C.☑ Valves are closed.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Ratchet adapter F30062582 1Feeler gage Y4342013 1

Preparatory steps1. Remove cover plate (2).2. Remove cylinder head cover (→ Page 118).3. Bar engine manually in engine direction of

rotation until the markings (1) are aligned.


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Checking valve clearance at twocrankshaft positions

1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valve

X Exhaust valve

1. Check TDC position of piston in cylinder A1:• If the rocker arms are not under load on cylinder A1, the piston is in firing TDC.• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with the engine cold:• Inlet = 0.4 mm;• Exhaust = 0.6 mm;.

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) asper diagram.

4. Use feeler gage to determine the distance between valve bridge and rocker arm.5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.


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Adjusting valve clearance1. Loosen locknut (1) and unscrew adjusting

screw (2) slightly.2. Insert feeler gage between valve bridge and

rocker arm.3. Readjust adjusting screw (2) so that the

feeler gage just passes through the gap.

4. Tighten locknut (1) applying the specified tightening torque, holding adjusting screw (2) firmly with screw‐driver.


Locknut Tightening torque 50 Nm

5. Insert feeler gage between valve bridge and rocker arm to verify that the gage just passes through thegap.

Result: If not, adjust valve clearance.

Final steps1. Remove barring device.2. For barring device removal, follow reverse sequence of working steps.


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6.4.2 Cylinder head cover – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027340 1Gasket (→ Spare Parts Catalog)

Preparatory steps1. Remove air filter (→ Page 142).2. Remove mounting bracket with control valves for exhaust turbocharger and air flap switching.

Removing and installing cylinderhead cover

1. Remove screws.2. Remove cylinder head cover with gasket

from cylinder head.3. Clean installation surface.4. Check condition of profile gasket in cylinder

head cover.5. Replace damaged gaskets.

6. Place cylinder head covers onto crankcase and tighten screws applying the specified tightening torque.


Screw Tightening torque 20 Nm

Final steps1. Install mounting bracket with control valves for exhaust turbocharger and air flap switching.2. Install air filter (→ Page 142).


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6.5 Injection Pump / HP Pump6.5.1 Injection pump – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Injection pump (→ Spare Parts Catalog)

Remove injection pump and install new one .u (→ Page 120)


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6.5.2 Injection pump – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Ratchet adapter F30027340 1Crow-foot box wrench F30027424 1Crow-foot box wrench F30027425 1Torque wrench, 0.5-5 Nm 0015384230 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)

DANGER Unguarded rotating and moving engine components.Risk of serious injury – Danger to life!• Before barring the engine, ensure that nobody is in the danger zone.


Preparatory steps1. Shut off fuel supply line before fuel filter.2. Remove Engine Control System (→ Page 178).3. Drain fuel (→ Page 130).4. Remove charge-air pipes and all seals.


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Removing injection pump1. Mark installation position of injection pump.2. Disconnect cabling (1) from injection pump.3. Remove fuel line (2).4. Unscrew securing screws of injection pump

by approx. 6 mm.• The pretensioned compression spring

presses the injection pump out of thecrankcase, if not:

a) turn crankshaft with engine barring de‐vice, (→ Page 104)• The pump cam presses the injection

pump out of the crankcase, if not:.

b) Carefully force out injection pump at therecess in the injection pump head.

5. Remove injection pump securing screws.6. Remove injection pump.7. Remove sealing rings from injection pump.8. After removal, seal all openings with suita‐

ble covers.

Installing injection pump1. Remove all blanking plugs and covers.2. Clean mating face of injection pump and

roller.Note: Sealing ring (1) Ø47 mm

3. Coat sealing ring (1) with grease (KlutheHakuform 30-10/Emulgier) and fit on to in‐jection pump.

Note: Sealing ring (2) Ø45 mm4. Coat sealing ring (2) with grease (Kluthe

Hakuform 30-10/Emulgier) and fit on to in‐jection pump.

5. Coat roller (arrowed) with engine oil.6. Clean sealing surface and fuel bores in

crankcase.7. Use barring tool (→ Page 104) to position

the pump cams on the camshaft at base cir‐cle.


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8. Install injection pump, observing marked in‐stallation position.

9. Install securing screws of injection pump and tighten with torque wrench to the specified torque.


Securing screw Tightening torque 60 Nm + 12 Nm

10. Install fuel line (2).11. Tighten union nut on the injection pump to the specified tightening torque using a torque wrench.

• Maximum permissible tightening torque: 35 Nm


Union nut Tightening torque 20 Nm + 5 Nm

12. Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torquewrench.• Maximum permissible tightening torque: 35 Nm



13. Install injection pump cabling (1).14. Use torque wrench to tighten screws to the specified tightening torque.


Screw Tightening torque 1.0 Nm ± 0.2 Nm

Final steps1. Remove barring device (→ Page 104).2. Clean mating faces on cylinder head and charge-air manifold.3. Check seals for damage and replace them, if required.4. Coat seals with grease (Kluthe Hakuform 30-10/Emulgier) and place onto cylinder head.5. Install charge-air pipes.6. Install Engine Control System (→ Page 178).7. Open fuel supply line before fuel filter.8. Vent fuel system (→ Page 131).


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6.6 Injection Valve / Injector6.6.1 Injector – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Injector (→ Spare Parts Catalog)

Remove injector and install new injector.u (→ Page 124)


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6.6.2 Injector – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Puller 3555890163/00Fuel suction device F30378207 1Torque wrench, 20-100 Nm F30026582 1Open end socket wrench F30025897 1Crow-foot box wrench F30027425 1Crow-foot box wrench F30027424 1Double-head box wrench F30011450 1Ratchet adapter F30027340 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)



Preparatory steps1. Remove cylinder head cover (→ Page 118).2. Drain fuel (→ Page 130).


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Removing injector1. Remove leak-off-fuel lines.2. Remove fuel line (3).3. Remove thrust screw (2).4. Pull off pressure pipe union (1).5. Extract fuel from the exposed bores using

the suction device.

6. Remove screw (2).7. Take off clamp (1).8. Screw puller into injector.9. Remove injector with puller.

10. Remove injector sealing ring using a self-made hook.

11. After removal, seal all openings with suita‐ble covers.


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Installing injector1. Remove all covers before installation.2. Clean sealing surface on cylinder head and

protective sleeve.3. Coat sealing ring (1) with grease and fit on‐

to injector.4. Coat sealing ring (2) with grease and fit on‐

to injector.5. Press injector into cylinder head by hand.

Result: • The pin is at 11-o'clock position to thetransversal axis of the engine.

• The pin is engaged in the recess of theclamp (4).

6. Install clamp (4) with screw (5), positioningit correctly.

Result: • Pin on injector is in the recess in theclamp.

• Forked clamp end is engaged in the cov‐er recess.

7. Tighten screw (5) of the clamp by hand.Result: Injector can still be turned.

8. Blow out fuel line (3) and pressure pipe un‐ion (1) with compressed air.

9. Coat sealing ring with grease and fit ontopressure pipe union (1).

10. Coat taper on pressure pipe union with en‐gine oil.

11. Insert pressure pipe union into cylinderhead until it is in contact with the sealingring.

12. Fully press in pressure pipe union (1) byhand.

13. Tighten thrust screw (2) with torque wrench to the specified tightening torque.


Thrust screw Tightening torque 40 Nm ±5 Nm

14. Use torque wrench to tighten screw for clamp at injector to the specified tightening torque.


Screw Tightening torque 50 Nm



Union nut Tightening torque 20 Nm +5 Nm


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17. Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torquewrench.


Union nut Tightening torque 20 Nm +5 Nm

18. Install leak-off-fuel lines.

Final steps1. Install cylinder head cover (→ Page 118).2. Vent fuel system (→ Page 131).


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6.7 Fuel System6.7.1 HP fuel line – Pressure pipe union replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Open end socket wrench F30025897 1Crow-foot box wrench F30027425 1Crow-foot box wrench F30027424 1Double-head box wrench F30011450 1Ratchet adapter F30027340 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933Engine oilPressure pipe union (→ Spare Parts Catalog)



Preparatory steps1. Remove cylinder head cover (→ Page 118).2. Drain fuel (→ Page 130).


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Replacing pressure pipe union1. Remove fuel line (3).2. Remove thrust screw (2).3. Pull off pressure pipe union (1).4. Coat sealing ring with grease (Kluthe Haku‐

form 30-10/Emulgier) and fit on to newpressure pipe union (1).

5. Blow out fuel line (3) with compressed air.6. Coat sealing cone of pressure pipe union

with engine oil.7. Insert pressure pipe union into cylinder

head until it is in contact with the sealingring.

8. Fully press in pressure pipe union (1) byhand.

9. Tighten thrust screw (2) with torque wrench to the specified tightening torque.


Thrust screw Tightening torque 40 Nm ± 5 Nm




12. Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torquewrench.



Final steps1. Install cylinder head cover (→ Page 118).2. Vent fuel system (→ Page 131).


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6.7.2 Fuel – Draining



Fuel – Draining1. Release threaded vent plugs on filter head.

2. Open nipple on fuel line and drain fuel intoappropriate container.

3. When fuel stops emerging from system,close nipple on fuel line.

4. Close vent plugs on filter head.


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6.7.3 Fuel system venting



Fuel system venting1. Unlock fuel priming pump, unscrew handle.

2. Open vent plugs on filter head.3. Operate the pump with the handle until fuel

without bubbles comes out of the vent plugsand the nipples.

4. Close vent plugs on filter head.


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5. Open nipple at fuel heat exchanger.6. Operate the pump with the handle until fuel

without bubbles comes out of the nipple.7. Close nipple at fuel heat exchanger.

8. Open nipple at fuel line.9. Operate the pump with the handle until fuel

without bubbles comes out of the nipple.10. Close nipple at fuel line.11. Lock fuel priming pump, screw in handle.


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6.8 Fuel Filter6.8.1 Fuel filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Oil filter wrench F30379104 1Diesel fuelEasy-change filter (→ Spare Parts Catalog)Synthetic ring (→ Spare Parts Catalog)




CAUTION Damage to component.Serious damage to plant!• For filter replacement with the engine running, operate the engine at low engine load.• The filter which is to be exchanged must be cut out for a brief period only.


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Fuel filter replacement with theengine stopped

1. Cut out the filter to be replaced.A Both filters cut in (operating position)B Left filter cut outC Right filter cut out

2. Unscrew switched off easy-change filterwith oil filter wrench.

3. Clean sealing surface on filter head.4. Check sealing ring of the new easy-change

filter and moisten it with fuel.5. Fit SOLAS shield (→ Page 18).6. Screw on easy-change filter and tighten by

hand.7. Set three-way cock to operating position for

both filters (normal position).8. Replace further fuel filters in the same way.9. Vent fuel system (→ Page 131).

Replacing fuel filter with the enginerunning

1. Shut down the filter to be replaced.2. Open the threaded vent plugs at the filter

head of the cut-out filter and make sure thatthe fuel filter is not pressurized.

3. Close threaded vent plugs.4. Unscrew switched off easy-change filter

with oil filter wrench.5. Clean sealing surface on filter head.6. Check sealing ring of the new easy-change

filter and moisten it with fuel.7. Fit SOLAS shield (→ Page 18).8. Screw on easy-change filter and tighten by

hand.9. Set three-way cock to operating position for

both filters (normal position).10. Replace further fuel filters in the same way.


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6.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge



Differential pressure gaugeadjustment

1. When installing the new filter element: alignadjustable pointer (2) with pressure-indicat‐ing pointer (3) of pressure gauge (1).

2. Verify that differential pressure is within thelimit.

Fuel prefilter – Checking differential pressure1. With the engine running at full load or rated power, read off pressure at gauge (1).2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of

pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 137).


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6.8.3 Fuel prefilter – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelSeal (→ Spare Parts Catalog)


Fuel prefilter – Draining1. Cut out the filter to be drained.

I Left filter cut inII Right filter cut in

2. Open threaded vent plug (5) of the filter tobe drained.

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and contaminants from the filteruntil pure fuel emerges.

5. Close drain valve (6).6. Remove screws securing the cover and

take off cover (2).7. Fill filter housing with clean fuel.8. Place new seal in cover (2).9. Fit cover with gasket and secure it with

screws.10. Cut in the cut-out filter again.11. Close threaded vent plug (5) when fuel

emerges from system.


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6.8.4 Fuel prefilter – Flushing

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelGasket (→ Spare Parts Catalog)




Flushing fuel prefilter1. Switch off contaminated filter.



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2. Open threaded vent plug (5) of the filter tobe flushed.

3. Unlock drain valve (6) by pressing toggle,open it and drain fuel.

Result: Fuel flows from filtered side back to the un‐filtered side, flushing the filter depositsdownwards out of the filter.

4. Close threaded vent plug (5) and drainvalve (6).

Filling fuel prefilter with fuel1. Stop engine (→ Page 91) and disable engine start.2. Remove screws securing the cover and take off cover (2).3. Fill filter housing with clean fuel.4. Place new gasket in cover (2).5. Fit cover with gasket and secure it with screws.6. Check differential pressure (→ Page 135).

Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ter (→ Page 139).


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6.8.5 Fuel prefilter – Filter element replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelFilter element (→ Spare Parts Catalog)Seal (→ Spare Parts Catalog)


Replacing filter element1. Cut out the contaminated filter.



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2. Open threaded vent plug (5) of contaminat‐ed filter.

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and contaminants from the fil‐ter.

5. Close drain valve (6).6. Remove screws securing the cover and

take off cover (2).7. Remove spring housing (4) and filter ele‐

ment (3).8. Insert new filter element (3) and spring

housing (4).9. Fill filter housing with clean fuel.

10. Place new seal in cover (2).11. Fit cover with gasket and secure it with

screws.12. Cut in the cut-out filter again.13. Close threaded vent plug (5) when fuel

emerges.14. Set adjustable pointer of differential pres‐

sure gauge (→ Page 135).


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6.9 Charge-Air Cooling6.9.1 Intercooler – Checking condensate drain line for coolant discharge and

obstruction




Intercooler – Checking condensatedrain line for coolant discharge andobstruction

1. With the engine running, check the conden‐sate drain line on engine driving end for airdischarge.

2. If no air emerges, remove condensate drainline and blow out with compressed air.

3. Replace obstructed drain line by new one.4. Install condensate drain line.5. If a large amount of coolant is continuously

discharged, the intercooler is leaking. Con‐tact Service.

Emergency measures prior to engine start with a leaking intercooler1. Remove injectors (→ Page 123).2. Bar engine manually (→ Page 104).3. Bar engine with starting system to blow out cylinder chambers (→ Page 105).4. Install injectors (→ Page 124).


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6.10 Air Filter6.10.1 Air filter – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter (→ Spare Parts Catalog)

Remove old air filter and install new air filter .u (→ Page 143)

Reset signal ring of service indicator .u (→ Page 144)


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6.10.2 Air filter – Removal and installation


Air filter – Removal and installation1. Loosen clamp (2).2. Remove air filter (3) and clamp (2) from

flange of intake housing (1).3. Verify that there are no objects in the flange

of the intake housing (1) and clean it.4. Place new air filter (3) with clamp (2) onto

intake housing (1).5. Tighten clamp (2).


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6.11 Air Intake6.11.1 Service indicator - Signal ring position check


Checking signal ring position1. If the signal ring is completely visible in the

control window (2), replace air filter(→ Page 142).

2. After installation of new filter, press resetbutton (1).

Result: Engaged piston with signal ring moves backto initial position.


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6.12 Starting Equipment6.12.1 Starter – Condition check


Checking starter condition1. Check securing screws of starter for secure seating and tighten if required.2. Check wiring (→ Page 172).


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6.13 Lube Oil System, Lube Oil Circuit6.13.1 Engine oil level – Check


Checking oil level prior to enginestart

1. Withdraw oil dipstick from guide tube andwipe it.

2. Insert oil dipstick into guide tube up to thestop, withdraw after approx. 10 secondsand check oil level.

3. Oil level must be between “min.” and “max.”marks.

Result: If there is no mark, mark the oil dipstick(→ Page 148).

4. If necessary, top up to "max." mark(→ Page 147).

5. Insert oil dipstick into guide tube up to thestop.

Checking oil level after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between “min.” and “max.” marks.

Result: If there is no mark, mark the oil dipstick (→ Page 148).4. If necessary, top up to "max." mark (→ Page 147).5. Insert oil dipstick into guide tube up to the stop.


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6.13.2 Engine oil – Change

Preconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temperature.☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine oilSealing ring (→ Spare Parts Catalog)


Oil change without semirotary hand pump: Draining oil at drain plug on oil pan1. Provide a suitable container to collect the oil.2. Remove drain plug and drain oil.3. Install drain plug with new sealing ring.4. Replace engine oil filter (→ Page 149).

Oil change with semirotary hand pump: Oil extraction1. Provide a suitable container to collect the oil.2. Extract all oil from oil pan using the semirotary hand pump.3. Replace engine oil filter (→ Page 149).

Filling with new oil1. Open cover on filler neck.2. Pour oil in at filler neck up to "max." mark at

oil dipstick.3. Close cover on filler neck.4. Check engine oil level (→ Page 146).5. After oil change and filter replacement, bar

engine with starting system (→ Page 105).


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6.14 Oil Filtration / Cooling6.14.1 Oil dipstick – Marking



Note: In the case of new engines and spare parts, oil dipsticks are delivered without marks.

Oil dipstick – Marking1. Draw-off or bleed out engine oil completely of oil pan.2. Withdraw oil dipstick.3. Fill in minimum oil quantity.4. Insert oil dipstick and withdraw it again.5. Mark a "Min." notch on the oil dipstick. Max. notch depth 1mm.6. Shorten oil dipstick.7. Fill in maximum oil quantity.8. Insert oil dipstick and withdraw it again.9. Mark a "Max." notch on the oil dipstick. Max. notch depth 1mm.


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6.14.2 Engine oil filter – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Oil filter wrench F30379104 1Engine oilOil filter (→ Spare Parts Catalog)Plastic ring (→ Spare Parts Catalog)




CAUTION Damage to component.Serious damage to plant!• For filter replacement with the engine running, operate the engine at low engine load.• The filter which is to be exchanged must be cut out for a brief period only.

Replacing oil filters on a shut-downengine

A Right filter cut outB Both filters cut in (normal operating

position)C Left filter cut out


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1. Stop engine (→ Page 91) and disable engine start.2. Cut out the filter to be replaced.3. Remove cut-out oil filter using the oil filter

wrench.4. Clean sealing surface on connecting piece.5. Check condition of new oil filter sealing ring

and coat it with oil.6. Fit SOLAS shield (→ Page 18).7. Screw on and tighten new engine oil filter

by hand.8. Replace other oil filters in the same way.9. Switch filter to normal position.

10. After each oil change and filter replace‐ment, crank engine with starting system(→ Page 105).

11. Check oil level (→ Page 146).

Replacing oil filters on a running engine1. Reduce engine speed to <1100 rpm.2. Remove cut-out oil filter using the oil filter wrench.3. Clean sealing surface on connecting piece.4. Check condition of new oil filter sealing ring and coat it with oil.5. Fit SOLAS shield (→ Page 18).6. Screw on and tighten new engine oil filter by hand.7. Replace other oil filters in the same way.8. Switch filter to normal position.9. Check oil level (→ Page 146).


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6.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Strap wrench F30379104 1Cold cleaner (Hakutex 50) 50622 1Filter sleeve (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)


Centrifugal oil filter – Rotor removal1. Release nuts (3).2. Remove housing cover (1).3. Remove complete rotor (2) from housing.


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Centrifugal oil filter – Cleaning andfilter-sleeve replacement

1. Remove nut, holding the rotor with a strapwrench.

2. Remove nut (1), washer (2), rotor cap (3)and sealing ring (4).

3. Remove sleeve (1).4. Measure the layer thickness of the oil resi‐

due.5. If maximum layer thickness (25 mm) is ex‐

ceeded, shorten maintenance interval.6. Clean rotor components and remove strain‐

ers (2).7. Wash standpipes (3) and nozzles (4) with

cleaner, blow out with compressed air.8. Insert the new filter sleeve with the smooth

surface facing the rotor cap.


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9. Fit new sealing ring (4).10. Set on rotor cap (3), observe marks.11. Fit washer (2).

12. Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.


Nut M18 x 1.5 Tightening torque 10 Nm

13. Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.


Nut M16 x 1.5 Tightening torque 40 Nm to 50 Nm

14. Insert complete rotor (2) into the housingand check for ease-of-movement.

15. Set housing cover (1) with new sealing ringonto lower section, observe marks.

16. Tighten nuts (3) crosswise and evenly.


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6.15 Coolant Circuit, General, High-Temperature Circuit6.15.1 Drain and venting points

Top view

1 Engine coolant vent2 Intercooler3 Overflow line

4 Engine coolant expansiontank

5 Fuel filter

6 Engine oil filter


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Left side

1 Engine coolant drain plug2 Engine coolant drain plug

3 Raw water pump drainplug


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Free end (KGS)

1 Three-way cock2 Fuel filter3 Fuel vent valve4 Raw water pump filling

plug5 Raw water pump drain

plug

6 Connection for oil extrac‐tion

7 Oil dipstick (connectionleft or right engine sideoptional)

8 Oil filler neck (connectionleft or right engine sideoptional)

9 Fuel priming pump


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Right side

1 Engine coolant drain plug2 Engine coolant drain plug3 Engine oil filter4 Fuel priming pump5 Raw water pump filling

plug



4 Leak-off-fuel tank


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Driving end (KS)

1 Engine coolant drain plug2 Oil filler neck (connection

left or right engine sideoptional)




6 Engine coolant drain plug

7 Fuel vent


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6.15.2 Engine coolant – Level check


WARNING Coolant is hot and under pressure.Risk of injury and scalding!• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at fillerneck:

1. Turn breather valve on coolant expansiontank counterclockwise up to the first stopand allow pressure to escape.

2. Continue to turn breather valve counter‐clockwise and remove.

3. Check coolant level (coolant must be visibleat the lower edge of the cast-in eye).

Checking coolant level at externalcooler:

1. Check coolant level (coolant must be visibleat marker plate).

2. If required, top up with treated engine cool‐ant (→ Page 162) .

3. Check proper condition of breather valveand clean sealing faces.

4. Fit breather valve on filler neck and close it.

Checking coolant level by means of level sensor:1. Switch engine control system ON and check display (coolant level is automatically monitored by the en‐

gine control system).2. If required, top up with treated engine coolant (→ Page 162) .


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6.15.3 Engine coolant – Change

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine coolant

Drain engine coolant.u (→ Page 161)

Fill with engine coolant.u (→ Page 162)


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6.15.4 Engine coolant – Draining



Preparatory steps1. Provide a suitable receptacle to catch the coolant.2. Switch off preheating unit.

Engine coolant draining1. Turn breather valve of coolant expansion

tank counterclockwise until the first stopand allow pressure to escape.


3. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

4. Open drain valves and/or drain plugs anddrain coolant at the following points:• Drain plug (4)• Crankcase (1)• Intercooler (6)• Exhaust-pipe elbow (5)• Heating connection (3)• Engine oil heat exchanger (2)

5. Close all open drain points.6. Place breather valve on filler neck and

close.


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6.15.5 Engine coolant filling


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Coolant


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Engine coolant filling1. Turn breather valve on coolant expansion

tank counterclockwise to first stop and allowpressure to escape.


3. Remove plug (required only for first fill).4. Pour coolant into engine until coolant level

reaches lower edge of cast-in eye of fillerneck.

5. Install plug.6. Check proper condition of breather valve

and clean sealing faces.7. Fit breather valve onto filler neck and close

it.8. Start the engine and operate it at idle speed

for some minutes.9. Check coolant level (→ Page 159) .


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6.15.6 HT coolant pump – Relief bore check



HT coolant pump – Relief borecheck

1. Check relief bore for oil and coolant dis‐charge.

2. Stop the engine (→ Page 91) and disableengine start.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour.4. If discharge exceeds the specified limits,

contact Service.


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6.15.7 Engine coolant – Sample extraction and analysis


Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1


Engine coolant – Sample extractionand analysis

1. Turn breather valve of filler neck on coolantexpansion tank counterclockwise to firststop and allow pressure to escape.


3. Draw off precipitated corrosion inhibitor oilfrom expansion tank and dispose of it.

4. Draw off approx. 1 liter coolant and drain in‐to a clean container.

5. Using the equipment and chemicals fromthe MTU test kit, examine coolant for:• antifreeze concentration;• corrosion inhibitor concentration;• pH value.

6. Fit breather valve on filler neck and close it.7. Change engine coolant (→ Page 161)ac‐

cording to the coolant operating timesspecified in the (→ MTU Fluids and Lubri‐cants Specifications A001061/..) .


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6.16 Raw Water Pump with Connections6.16.1 Raw water pump – Relief bore check




Raw water pump – Relief borecheck

1. Check relief bore for oil and coolant dis‐charge.

2. Clean relief bore using a wire if required.• Permissible coolant discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour.3. If discharge exceeds the specified limits,

contact Service.


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6.17 Belt Drive6.17.1 Drive belt – Condition check

Preconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.

Drive belt – Condition check

Item Findings ActionDrive belt A Singular cracks NoneDrive belt Belt is oily, shows signs of over‐

heatingReplace(→ Page 169)

Drive belt B Cracks on entire circumferenceDrive belt C Chunking


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6.18 Battery-Charging Generator6.18.1 Battery-charging generator drive – Drive belt check and adjustment


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Assembly device F6559691 1

Preparatory steps1. Remove limit switch (4).2. Remove indicator (1).3. Remove screws (3) of protective cover (2).4. Remove protective cover.5. Check drive belt condition (→ Page 166)

Belt drive – Checking distance1. Measure distance (A) with assembly de‐

vice.2. If measured value of distance (A) is not

within the tolerance of 98 mm ± 1.5 mm, re‐adjust belt tension.


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Adjusting belt tension1. Hold adjustment lever (2) at square (5).2. Rotate adjusting lever until drive belt (4) is released.3. Loosen screws (1) and (3).4. Use assembly device to adjust distance (A) by turning adjustment lever (2).5. Tighten screws (1) and (3).6. Measure distance (A) with assembly device.

Final steps1. Install protective cover (2).2. Install securing screws (3) of protective cov‐

er (2).3. Install indicator (1).4. Install limit switch (4).


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6.18.2 Battery-charging generator drive – Drive belt replacement


Preparatory steps1. Remove limit switch (4).2. Remove indicator (1).3. Remove screws (3) of protective cover (2).4. Take off protective cover.

Replacing drive belt1. Counterhold adjustment lever (2) at square

(5) using a square socket wrench.2. Use the square wrench to turn the adjust‐

ment lever until the drive belt (4) is re‐leased.

3. Take off drive belt.4. Make sure that the belt pulleys are clean.5. Fit new drive belt.6. Adjust belt tension (→ Page 167).


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Final steps1. Install guard.2. Install securing screws (3) of protective cov‐

er (2).3. Install indicator (1).4. Install limit switch (4) (→ Page 175).


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6.19 Engine Mounting / Support6.19.1 Engine mounting – Checking condition of resilient mounts

Preconditions☑ Engine is stopped and starting disabled.☑ Engine is filled with engine coolant and engine oil.☑ Engine is under static load.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Feeler gage Y4342013 1Vernier caliper 2000275 1

Engine mounting – Checking thecondition of resilient mounts

1. Measure height setting (b) with feeler gage.2. Measure dimension (a) with calipers.3. Calculate permissible value of dimension

(a), considering the measured value ofheight adjustment (b):• Reference values: The permissible value

of dimension (a) is 144 mm when (b) = 5mm

• When measured height setting (b) = 6mm, the permissible value of (a) is 145mm.

• When measured height setting (b) = 4mm, the permissible value of (a) is 143mm.

4. Replace the resilient mount, if the meas‐ured value of dimension (a) is lower thanthe permissible value.


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6.20 Wiring (General) for Engine/Gearbox/Unit6.20.1 Engine wiring – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol X00058037 1

Engine wiring – Check1. Check securing screws of cable clamps on engine and tighten loose threaded connections.2. Ensure that cables are fixed in their clamps and cannot swing freely.3. Check that cable ties are firm, tighten loose cable ties.4. Replace faulty cable ties.5. Visually inspect the following electrical line components for damage:

• connector housings;• contacts;• sockets;• cables and terminals;• plug-in contacts.

6. (→ Contact Service) if cable conductors are damaged.Note: Close male connectors that are not plugged in with the protective cap supplied.

7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.8. Ensure that all sensor connectors are securely engaged.


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6.21 Accessories for (Electronic) Engine Governor / ControlSystem

6.21.1 Engine control unit and connectors – Cleaning

Preconditions☑ Engine shut down and starting disabled.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers 0135315483 1Isopropyl alcohol 46181 1

Cleaning engine control unit andconnectors

1. Remove heavy soiling from housing surfacewith isopropyl alcohol.

2. Remove dirt from surface of connectors (1),connector sockets and shrink-formed com‐ponents (2) using a cloth moistened withisopropyl alcohol.

3. Check legibility of cable labels. Clean or re‐place illegible labels.

Cleaning heavily soiled connectorson engine control unit

1. Use connector pliers (2) to disengage bayo‐net union nut (4) and withdraw connector(3).

2. Clean connector housings, connector sock‐et housings (1) and all contacts with iso‐propyl alcohol.

3. When connectors, sockets and all contactsare dry: Fit connectors and check enginecontrol unit plug connections (→ Page 176).


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6.21.2 Engine monitoring unit and connectors – Cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers 0135315483 1Isopropyl alcohol 46181 1

Cleaning engine monitoring unitand connectors

1. Remove coarse dirt from housing surfacewith isopropyl alcohol.

2. Remove dirt from surface of connectors (1),connector sockets and shrink sleeves (2)using a cloth moistened with isopropyl alco‐hol.

3. Check legibility of cable labels. Clean or re‐place illegible labels.

Cleaning severely contaminatedEMU connectors

1. Use connector pliers (2) to disengage bayo‐net union nut (4) and withdraw connector(3).

2. Clean connector housings, connector sock‐et housings (1) and all contacts with iso‐propyl alcohol.

3. When connectors, sockets and all contactsare dry: Replace connectors and checkplug connections on EMU (→ Page 177).


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6.21.3 Start interlock limit switch – Check


Note: Being in OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started.Start interlock limit switch – Check

1. Check if switch housing (1) and cover plate(3) are mounted and the switch (2) is in ON-position.

2. If switch housing (1) and/or cover plate (3)is/are not mounted:• Secure cover plate (3) with screws.• Then install switch housing (1) with

screws, ensuring that the switch (2) isactuated by the cover plate (3).

3. If switch housing (1) and cover plate (3) aremounted, but switch (2) is in OFF-position:• Make certain that the cover plate (3) at

the side of the switch (2) is not distorted.• Loosen switch housing (1) and fit it with

screws in a position providing that theswitch (2) is ON.

• If this is not feasible, contact Service.


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6.21.4 ECU – Checking plug connections



Checking plug connections on ECU1. Use connector pliers (3) to make certain

that all plug connections of ECU are se‐curely seated.

2. Tighten loose bayonet union nuts (2) withconnector pliers (3) by turning them clock‐wise until they lock into place.

3. Make sure that unassigned sockets areclosed off with cover caps.

4. Contact Service if bayonet union nuts aredefective.


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6.21.5 Engine monitoring unit, plug connections – Check



Checking engine monitoring unitplug connections

1. Use connector pliers (3) to make certainthat all engine monitoring unit plug connec‐tions are securely seated.

2. Tighten loose bayonet union nuts (2) withconnector pliers (3) by turning them clock‐wise until they lock into place.

3. Make sure that unassigned sockets areclosed off with cover caps.

4. If bayonet couplings are defective, contactService.


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6.21.6 Engine control unit – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers 0135315483 1Covering caps for Cannon sockets

Removing control unit from engine1. Note or mark assignment of cables to con‐

nector sockets.2. Use connector pliers (2) to disengage the

bayonet union nuts (4) of the connectors (3)by turning them counterclockwise.

3. Remove all connectors.4. Close connector sockets with appropriate

covering caps (1).


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5. Disconnect ground strap from engine con‐trol unit grounding stud (7).

6. If the screws (4) are easily accessible:1. Remove screws (4).2. Remove engine control unit housing (3)

from mounting plates (2).3. Unscrew mounting plates (2), cable

shock absorbers (5) and further secur‐ing parts (6) as one unit from engine.

7. If the screws (4) are not easily accessible:1. Unscrew screws (1).2. Remove engine control unit housing (3)

together with mounting plates (2).3. Unscrew cable shock absorbers (5) and

further securing parts (6) as one unitfrom engine.

Installing engine control unit on engine1. Install in reverse order. Ensure correct assignment of plugs and sockets.2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they lock into place.


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6.22 Emergency Instrumentation (Local Operating Panel)6.22.1 LOP and connectors – Cleaning

Preconditions☑ Engine shut down and starting disabled.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol 46181 1

Cleaning LOP1. Wipe LCD display with dry cloth, without applying excessive pressure.2. Remove dirt from keys using isopropyl alcohol.3. Remove heavy soiling from housing surface with isopropyl alcohol.

Cleaning connectors on LOP1. Remove dirt from connector and socket surfaces using isopropyl alcohol.2. Check legibility of cable labels. Clean or replace illegible labels.


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6.22.2 LOP – Visual inspection


Preparatory steps1. If READY FOR OPERATION pushbutton is illuminated brightly, press switch briefly.

Result: READY FOR OPERATION pushbutton returns to basic brightness.2. Switch master power switch to OFF.3. Disconnect battery in accordance with battery manufacturer's instructions.

Checking housing and internalassemblies for secure seating

1. Open LOP front door.2. Check securing screws (1, 3, 4, 7) for firm

seating. Tighten loose threaded connec‐tions.

3. Check internal assemblies for firm seating,this applies in particular to printend circuitboard (2) and PIMs (5, 6). Tighten loosethreaded connections.

4. Close LOP front door.

Checking plug connections1. Check all connected cables to verify that

the two securing elements (1) are engagedon the lugs (2) so that the respective maleconnector (3) is held firmly in place in thesocket.

2. If this is not the case, press the securing el‐ements (1) concerned in the direction of thearrow until they engage noticeably.


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Checking unassigned connectorsockets

1. Ensure that non-assigned connector sock‐ets are protected with covering caps.

2. Make certain that the two securing ele‐ments (1) are engaged in the lugs (2) sothat the covering cap (3) is held firmly inplace in the socket.

3. If this is not the case, press the securing el‐ements (1) concerned in the direction of thearrow until they engage noticeably.

Checking pushbuttons and display1. Pushbuttons: Ensure that

• Pushbutton caps are not damaged(cracks or similar damage)

• Pushbuttons move easily;• Pushbutton housings are seated secure‐

ly;• Seals (2) between PAN control panels

and LOP housing are not damaged.2. Display: Ensure that

• Front glass is not damaged or pressedin;

• Seal (1) between display housing andLOP housing is not damaged.

3. Have damaged components replaced im‐mediately by Service.

Performing lamp test1. Connect battery in accordance with battery

manufacturer's instructions.2. Switch master power switch to ON.3. Switch on Engine Control System.4. Hold down LAMP TEST pushbutton:

Result: Indicators and controls light up.5. Have damaged lamps immediately replaced

by Service.


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6.22.3 LOP – Test procedures


Preparatory steps1. Connect battery in accordance with battery

manufacturer's instructions.2. Switch master power switch to ON.3. Switch on engine management system

ECS-5.Result: • LOCAL OPERATION pushbutton (1) is il‐

luminated brightly (local control mode isactive);.

Switching between Local and Remote mode (automatic on-board network)1. Press LOCAL OPERATION pushbutton (1).

Result: • LOCAL OPERATION pushbutton (1) flashes: Setting does not correspond with feedback signal fromEngine Control Unit.

• LOCAL OPERATION pushbutton (1) is illuminated at basic brightness: Remote mode active.2. Press LOCAL OPERATION pushbutton (1) again.

Result: LOCAL OPERATION pushbutton (1) is illuminated brightly (Local mode is active);.


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Overspeed test with the engine atstandstill

Note: Overspeed test with the engine at standstillcan only be carried out if the engine isequipped with Engine Monitoring Unit.

1. Press OVERSPEED TEST illuminatedpushbutton (3). Observe speed limit andspeed simulated by Engine Monitoring Uniton display.

Result: • Engine Control Unit is de-energized bythe safety system.

• Engine governing is completely deacti‐vated.

• On engines with emergency air-shutoffflaps: Flaps close.

• EMERGENCY STOP illuminated push‐button (2) flashes;. Alarm signalling byhorn, flashing light etc. is initiated.ALARM ACKNOWLEDGE pushbutton(1) is illuminated brightly.

2. Press ALARM ACKNOWLEDGE pushbut‐ton (1).

Result: Audible and visual alarm signaling stops.3. Press ALARM ACKNOWLEDGE pushbut‐

ton (1) again.Result: Power supply to Engine Control Unit is pro‐

vided.4. On engines with emergency air-shutoff

flaps: Open flaps.

Emergency stop simulation with theengine at standstill

1. Open cap of EMERGENCY STOP pushbut‐ton (2).

2. Press EMERGENCY STOP pushbutton (2).Result: • Engine Control Unit is deenergized by

the safety system.• Engine governing is completely deacti‐

vated.• On engines with emergency air-shutoff

flaps: Flaps close.• EMERGENCY STOP pushbutton (2)

flashes;. Alarm signalling by horn, flash‐ing light etc. is initiated. ALARM AC‐KNOWLEDGE pushbutton (1) is illumi‐nated brightly.

3. Press ALARM ACKNOWLEDGE pushbut‐ton (1).

Result: Audible and visual alarm signaling stops.4. Press ALARM ACKNOWLEDGE pushbut‐

ton (1) again.Result: Power supply to Engine Control Unit is pro‐

vided.5. On engines with emergency air-shutoff

flaps: Open flaps.


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7 Appendix A7.1 Abbreviations

Abbrevia‐tion

Meaning Explanation

AL Alarm Alarm (general)ANSI American National Standards InstituteATL Abgasturbolader TurbochargerBR Baureihe Engine SeriesCAN Controller Area NetworkDIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same

time identifier of German standards (DIN = "Deut‐sche Industrie-Norm")

DIS Display UnitDL Default Lost Alarm: Default CAN bus failureECS Engine Control SystemECU Engine Control UnitEDM Engine Data ModuleEMU Engine Monitoring UnitFLS Fluids and Lubricants Specification MTU Publication No. A01061/..HI High Alarm: Measured value exceeds 1st maximum limitHIHI High High Alarm: Measured value exceeds 2nd maximum lim‐

itHT High TemperatureICFN ISO - Continuous rating - Fuel stop

power - NetPower specification in accordance with DIN-ISO3046-7

IDM Interface Data ModuleIMO International Maritime OrganisationISO International Organization for Stand‐

ardizationKGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204KS Kraftseite Engine driving end in accordance with DIN ISO

1204LCD Liquid Crystal Display, Liquid Crystal

DeviceLCU Local Control Unit LOP subassemblyLED Light Emitting DiodeLMU Local Monitoring Unit LOP subassemblyLO Low Alarm: Measured value lower than 1st minimum

limitLOLO Low Low Alarm: Measured value lower than 2nd minimum

limit

MS150031/03E 2011-10 | Appendix A | 185

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Abbrevia‐tion

Meaning Explanation

LOP Local Operating PanelLOS Local Operating StationMCS Monitoring and Control SystemMG MessageMPU Microprocessor Unit, Microprocessing

UnitOT Oberer Totpunkt Top dead center (TDC)P-xyz Pressure-xyz Pressure measuring point xyzPAN PanelPIM Peripheral Interface ModuleRCS Remote Control SystemRL Redundancy Lost Alarm: Redundant CAN bus failureSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSDAF Shut Down Air FlapsSS Safety System Alarm initiated by safety systemSSK Schnellschlussklappe(n) Emergency air-shut-off flapsSPC Spare Parts CatalogT-xyz Temperature-xyz Temperature measuring point xyzTC Tools CatalogTD Transmitter DeviationUT Unterer Totpunkt Bottom dead center (BDC)

186 | Appendix A | MS150031/03E 2011-10

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7.2 MTU contacts/service partners

ServiceOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters ensures fast and direct support on site and the high availability of our products.

Local supportExperienced and qualified specialists place their knowledge and expertise at your disposal.

For locally available support, go to the MTU internet site: http://www.mtu-online.com

24h hotlineWith our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you- either during operation, for preventive maintenance, corrective work in case of malfunction or changedoperating conditions, or for spare parts supply.Your contact at Headquarters:[email protected]

Spare parts serviceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart at the right time at the right place.With this aim in mind, we can call on a globally networked spares logistics system- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐tives and contractual workshops.Your contact at Headquarters:E-mail: [email protected]: +49 7541 908555Fax: +49 7541 908121

MS150031/03E 2011-10 | Appendix A | 187

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8 Appendix B8.1 Special Tools

Assembly device

Part No.: F6559691Qty.:Used in:

1 6.18.1 Battery-charging generator drive – Drive belt check and adjustment (→ Page167)

Connector pliers

Part No.: 0135315483Qty.:Used in:

1 6.1.2 Engine – Barring with starting system (→ Page 105)

Qty.:Used in:

1 6.21.1 Engine control unit and connectors – Cleaning (→ Page 173)

Qty.:Used in:

1 6.21.2 Engine monitoring unit and connectors – Cleaning (→ Page 174)

Qty.:Used in:

1 6.21.4 ECU – Checking plug connections (→ Page 176)

Qty.:Used in:

1 6.21.5 Engine monitoring unit, plug connections – Check (→ Page 177)

Qty.:Used in:

1 6.21.6 Engine control unit – Removal and installation (→ Page 178)

Crow-foot box wrench


1 6.5.2 Injection pump – Removal and installation (→ Page 120)

Qty.:Used in:

1 6.6.2 Injector – Removal and installation (→ Page 124)

Qty.:Used in:

1 6.7.1 HP fuel line – Pressure pipe union replacement (→ Page 128)

Crow-foot box wrench



Qty.:Used in:


Qty.:Used in:


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Double-head box wrench



Qty.:Used in:


Feeler gage

Part No.: Y4342013Qty.:Used in:

1 6.4.1 Valve clearance – Checking and adjusting (→ Page 115)

Qty.:Used in:

1 6.19.1 Engine mounting – Checking condition of resilient mounts (→ Page 171)

Fuel suction device



MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 6.15.7 Engine coolant – Sample extraction and analysis (→ Page 164)

Oil filter wrench


1 6.8.1 Fuel filter – Replacement (→ Page 133)

Qty.:Used in:

1 6.14.2 Engine oil filter – Replacement (→ Page 149)

Open end socket wrench



Qty.:Used in:


Puller

Part No.: 3555890163/00Qty.:Used in:

6.6.2 Injector – Removal and installation (→ Page 124)

Ratchet


1 6.1.1 Engine – Barring manually (→ Page 104)

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Ratchet adapter


1 6.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacement (→ Page 110)

Qty.:Used in:

1 6.3.3 Crankcase breather – Oil separator replacement, diaphragm check and replace‐ment (→ Page 113)

Qty.:Used in:

1 6.4.2 Cylinder head cover – Removal and installation (→ Page 118)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:


Ratchet adapter



Rigid endoscope

Part No.: Y20097353Qty.:Used in:

1 6.2.1 Cylinder liner – Endoscopic examination (→ Page 106)

Socket


1 6.1.1 Engine – Barring manually (→ Page 104)

Steam jet cleaner

Part No.: -Qty.:Used in:

1 3.9 Plant – Cleaning (→ Page 94)

Strap wrench


1 6.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 151)

Torque wrench, 0.5-5 Nm



190 | Appendix B | MS150031/03E 2011-10

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Torque wrench, 20-100 Nm



Qty.:Used in:


Qty.:Used in:







1 6.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacement (→ Page 110)

Qty.:Used in:

1 6.3.3 Crankcase breather – Oil separator replacement, diaphragm check and replace‐ment (→ Page 113)

Qty.:Used in:

1 6.4.2 Cylinder head cover – Removal and installation (→ Page 118)

Vernier caliper


1 6.19.1 Engine mounting – Checking condition of resilient mounts (→ Page 171)

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8.2 ConsumablesCleaner (Hakupur 312)


1 3.9 Plant – Cleaning (→ Page 94)

Cold cleaner (Hakutex 50)


1 6.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 151)

Coolant

Part No.:Qty.:Used in:

6.15.5 Engine coolant filling (→ Page 162)

Covering caps for Cannon sockets


6.21.6 Engine control unit – Removal and installation (→ Page 178)

Diesel fuel


6.8.1 Fuel filter – Replacement (→ Page 133)

Qty.:Used in:

6.8.3 Fuel prefilter – Draining (→ Page 136)

Qty.:Used in:

6.8.4 Fuel prefilter – Flushing (→ Page 137)

Qty.:Used in:

6.8.5 Fuel prefilter – Filter element replacement (→ Page 139)

Engine coolant


6.15.3 Engine coolant – Change (→ Page 160)

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Engine oil


6.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacement (→ Page 110)

Qty.:Used in:

6.7.1 HP fuel line – Pressure pipe union replacement (→ Page 128)

Qty.:Used in:

6.13.2 Engine oil – Change (→ Page 147)

Qty.:Used in:

6.14.2 Engine oil filter – Replacement (→ Page 149)

Fuel


6.3.2 Crankcase breather – Cleaning oil separator element (→ Page 112)

Grease (Kluthe Hakuform 30-10/Emulgier)

Part No.: X00029933Qty.:Used in:

6.5.2 Injection pump – Removal and installation (→ Page 120)

Qty.:Used in:


Qty.:Used in:

6.7.1 HP fuel line – Pressure pipe union replacement (→ Page 128)

Isopropyl alcohol

Part No.: X00058037Qty.:Used in:

1 6.20.1 Engine wiring – Check (→ Page 172)

Isopropyl alcohol


1 6.21.1 Engine control unit and connectors – Cleaning (→ Page 173)

Qty.:Used in:

1 6.21.2 Engine monitoring unit and connectors – Cleaning (→ Page 174)

Qty.:Used in:

1 6.22.1 LOP and connectors – Cleaning (→ Page 180)

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8.3 Index12V 2000 M40A engine data: Engine-mounted heat ex‐

changer, reference conditions: 25 °C intake air tem‐perature 46

12V 2000 M40A engine data: Engine-mounted heat ex‐changer, reference conditions: 45 °C intake air tem‐perature 43

12V 2000 M40A engine data: Separate heat exchanger,reference conditions: 25 °C intake air temperature 49

12V 2000 M40A engine data: Separate heat exchanger,reference conditions: 45 °C intake air temperature 52

16V 2000 M40A engine data: engine-mounted heat ex‐changer, reference conditions: 25 °C intake air tem‐perature 55


16V 2000 M40A engine data: separate heat exchanger,reference conditions: 25 °C intake air temperature 61


16V 2000 M40B engine data, engine-mounted heat ex‐changer, reference condition: 25 °C intake air temper‐ature 70


16V 2000 M40B engine data, separate heat exchanger,reference condition: 25 °C intake air temperature 76






AAbbreviations 185After stopping the engine 93Air filter– Removal and installation 143– Replacement 142

BBattery-charging generator drive– Adjustment 167– Check 167Battery-charging generator drive – Drive belt replace‐

ment 169

CCentrifugal oil filter – Cleaning and filter-sleeve replace‐

ment 151Connectors– Cleaning 174Contacts 187Crankcase breather– Cleaning oil separator element 112– Diaphragm check 110– Oil separator element replacement 110Crankcase breather – Oil separator replacement, dia‐

phragm check and replacement 113Cylinder head cover – Removal and installation 118Cylinder liner– Endoscopic examination 106– Instructions and comments on endoscopic and visual

examination 108

DDrain and venting points 154Drive belt– Condition check 166

EECU– Checking plug connections 176Emergency stop from LOP 92Engine– Stopping at the LOP 91– Wiring check 172Engine control unit– Removal and installation 178Engine control unit and connectors– Cleaning 173Engine coolant– Change 160– Draining 161Engine coolant filling 162Engine coolant – Level check 159Engine coolant – Sample extraction and analysis 164ENGINE DATA 12V 2000M41A/B 79, 82Engine monitoring unit– Cleaning 174Engine monitoring unit, plug connections – Check 177Engine mounting – Checking condition of resilient

mounts 171Engine oil– Change 147Engine oil filter – Replacement 149Engine oil level – Check 146Engine side and cylinder– designations 28Engine wiring– Check 172Engine – Barring manually 104Engine – Main dimensions 29

194 | Appendix B | MS150031/03E 2011-10

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FFire and environmental protection 15Firing order 30Fluids and lubricants 15Fuel– Prefilter

– Differential pressure gauge - Check and adjust‐ment 135

– Draining 136– Filter element replacement 139

– prefilter – Flushing 137

Fuel filter– Replacement 133Fuel prefilter– Differential pressure gauge

– Check and adjustment 135– Draining 136– Filter element

– Replacement 139– Flushing 137Fuel system venting 131Fuel – Draining 130

GGeneral conditions 8

HHP fuel line – Pressure pipe union replacement 128HT coolant pump – Relief bore check 163

IInjection pump – Removal and installation 120Injector– Replacement 123Injector – Removal and installation 124Intercooler – Checking condensate drain line for coolant

discharge and obstruction 141

LLOP– Test procedures 183LOP alarms 99LOP and connectors– Cleaning 180LOP – Controls 85LOP – Visual inspection 181

MMaintenance and repair work– Safety requirements 13Maintenance task reference table [QL1] 95MTU contact persons 187

OOil dipstick – Marking 148Operational checks 90

PPersonnel and organizational requirements 9Plant– Cleaning 94Product description 18Putting the engine into operation (out-of-service period

> 3 months) 87Putting the engine into operation after scheduled out-of-

service period 88

RRaw water pump – Relief bore check 165

SSafety instructions 17Series 2000 M40A/B - M41A/B 27Service indicator– Signal ring position check 144Service partners 187Start interlock limit switch– Check 175Starter– Condition check 145Starting the engine from LOP 89

TTransport 10Troubleshooting 96

VValve clearance – Checking and adjusting 115

WWiring - engine– Check 172

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Documents

Operating Instructions Diesel engine - MTU · PDF fileOperating Instructions Diesel engine 8 V 2000 M40A, 8 V 2000 M40B 12 V 2000 M40A, 12 V 2000 M40B 12 V 2000 M41A, 12 V 2000 M41B